Systems Engineering Implementation
In Launch Vehicle Development Programs
Timothy T. Chen
Spacecraft & Vehicle Systems Department
Marshall Space Flight Center
Page 2
Launch Vehicle Project Challenges
• Design of a new launch vehicle is a large complex system development project.
• Its probability of success is often handicapped by: Complex requirement development (creep) process. Conflicting stakeholders’ expectations that often surfaced late in the
project design cycle. Acquisition strategy. Inherent nature of technology development risks in the project. Complex technical integration & interfaces across major elements. High initial non-recurring cost for capital investments
Often higher than what the stakeholders are willing to tolerate.
Limited schedule to demonstrate success before the project is in risk of being cancelled.
Page 3
Project Manager’s Headaches
• The Project Manager’s challenge is further aggravated when faced with the following issues: Lack of experienced and knowledgeable staff.
Launch vehicle design projects come once in a couple, to several, decades. Experienced & seasoned professionals, especially in project management & systems engineering with proven success in executing projects at the level of technical complexity, are limited.
Limited supply chain available from prime contractors to component suppliers.
Commercial Off-The-Shelf (COTS) and “Heritage” hardware do not mean “Plug-n-Play”.
Iterations and “spiral” design approach can be very costly to the Project Manager.
Antiquated in-house processes and procedures Do not keep up with the advances in project management & acquisition
practices.
Page 4
How can System Engineering help?
• The Systems Engineer is your technical manager for the Project Defines the phases the scope of the total effort Establishes the technical baseline and future modifications (upgrades) Provides qualified personnel and processes to Systems Engineering &
Integration (SE&I) in all top level system activities• So, you as Project Manager can focus on other tough problems!
A juggling act !
Scope
Project Manager
Staff/ HR
Quality
Sub-contracts
TimeCost
RiskContracts
Communication
Stakeholders
• Engineer the System Requirements
Analysis / Definition / Validation
Functional Analysis & Allocation
Synthesis of Designs
Evaluation of Alternatives
Requirements Verification
• Planning and Control
Organizing & Planning SEMP, IMP/IMS
Requirements Management
Interface Management Baseline Management Affordability Decision Making
Risk Management Trade Studies TPMs
Metrics Management Reviews
Systems Engineering Functions
Drive Technical Solution Technical Management
• Produce the System Integrated across
all systems and components
Product Life Cycle
Product Integration Verification Validation Transition
Realize Product
Page 6
Systems Engineering throughout the Product Life Cycle and at each Level
1 SYSTEM
2 SEGMENT
3 SUBSYSTEM
4 ELEMENT
5 COMPONENT
MAJOR MILESTONESMCR Mission Concept ReviewACR Alternative Concept ReviewSRR System Requirements ReviewSDR System Design ReviewPDR Preliminary Design ReviewCDR Critical Design ReviewFRR Flight Readiness Review PRR Production Readiness ReviewORR Operational Readiness ReviewDR Decommissioning Review
MISSIONANALYSIS
DEFINITION
DEFINEMISSION
REQUIREMENTS
CONCEPT DEFINITION
PRELIMINARYDEFINITION
DETAILED DEFINITION
FIRSTARTICLE
PRODUCTIONCONCEPT DEVELOPMENT
OPERATIONS/SUPPORT
MCR ACR SRR SDR PDR CDR FRR/PRR ORR DR
SE process used at each system level and throughout the product life cycle.
Page 7
NASA Systems Engineering Process
• NASA Guiding Documents NPR 7123.1A - NASA Systems Engineering Processes and
Requirements w/Change 1 (11/04/09) Systems Engineering NPR Implementation Plan SP-2007-6105 NASA Systems Engineering Handbook Project System Engineering Management Plan (SEMP)
Page 8
NASA Governing Documents
From: “NPR 7123.1A Overview”
• Three elements that make up NASA systems engineering capability Common Technical Processes Tools and Methods Workforce
NASA Systems Engineering Framework
NPR 7123.1A, Figure 1.1
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NASA Systems Engineering Engine
NPR 7123.1A, Figure 3.1
Page 11
Application of SE Engine Processes within System Structure
NPR 7123.1A, Figure 3.2
Page 12
Recommendations for Project Managers
• Hire Experienced & Knowledgeable Staff Multidisciplinary SEs (domain/mission/product experts) Apply the “TRL” process to your key personnel Get expert advices
Non-Advocate Reviews, industry advisory groups, etc. Not just technical, but also on management practices
• Plan, plan, plan … then plan some more Failure to plan = Plan to fail Unrealistic schedule = cost over-run
Page 12
SPACE TRANSPORTATION SYSTEMS BREAKDOWN STRUCTURE (SBS) TEMPLATE
SB
S In
de
ntu
red
No
. (1
st L
vl)
Sp
ace
Tra
nsp
ort
atio
n
Arc
hite
ctu
ral C
on
cep
t
SB
S In
de
ntu
red
No
. (2
nd
Lvl
)S
pa
ce T
ran
spo
rta
tion
Ve
hic
le
Ele
me
nt
SB
S In
de
ntu
red
No
. (3
rd L
vl)
Ge
ne
ric
De
sig
n D
isci
plin
es
SB
S In
de
ntu
red
No
. (4
th L
vl)
Ge
ne
ric
Fu
nct
ion
SB
S In
de
ntu
red
No
. (5
th/6
th
Lvl
) Generic Function Description (SBS 5th/6th
Level)1.0 System Architectural Concept Name
1.1 Vehicle Element (e.g., Booster, Orbiter, Payload element, repeat as needed for elements)1.1.1 Airframe Structure & Mechanisms
1.1.2 Propulsion 1.1.3 Power Management
1.1.4 Thermal Management1.1.5 Guidance, Navigation and Control
1.1.6 Communications, Control and Health Management1.1.7 Life Support
1.1.8 Environmental and Safety Management
1.2 Vehicle Elements Integration (Booster, Orbiter, TLI element, Planet or Moon Decent/Ascent element)1.2.1 Element to element structural attachment
1.2.2 Element to element communication1.2.3 Provide monitoring & control of safe environment between elements
1.2.4 Element to Element Separation
1..31.3.1 Flight Element Processing1.3.2 Payload Element Processing1.3.3 Integrated Processing
1.3.4 Flight and Ground Traffic Control and Safety Management1.3.5 Ground Infrastructure Support and Management
Ground Infrastructure Element(s)
VEHICLE
INTERFACE
GROUND
FBS
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
C D E F G H I
1.1.2 Propulsion 1.1.2.1 Booster/Planetary Ascent Propulsion
1.1.2.1.1 Fill & Drain 1.1.2.1.1.1 Oxidizer F&D system 1.1.2.1.1.2 Fuel F&D system t
1.1.2.1.2 On-Board Propellant Storage1.1.2.1.2.1 Oxidizer tank 1.1.2.1.2.2 Fuel tank
1.1.2.1.3 Cryogenic On-Board Propellant and hardware Conditioning for Engine Start1.1.2.1.3.1 Oxidizer bleed or bubbling system to provide thermal conditioning1.1.2.1.3.2 Fuel bleed and fluid circulating system to provide thermal conditioning
1.1.2.1.4 Storable Propellant Conditioning for Engine Start1.1.2.1.4.1 Engine oxidizer feed system fill & bleed1.1.2.1.4.2 Engine fuel feed system fill & bleed
1.1.2.1.5 On-Board Purge1.1.2.1.5.1 Engine oxidizer system purge & conditioning to remove contamination1.1.2.1.5.2 Engine fuel system purge & conditioning to remove contamination
1.1.2.1.6 Pressurization1.1.2.1.6.1 Oxidizer tank pressurization 1.1.2.1.6.2 Fuel tank pressurization
Launch Systems (Level II) Functional Breakdown Structure (FBS)
Propulsion Subsystems (Level VI) Functional Breakdown Structure (FBS)
1.3.1Propulsion Subsystem
Hardware
1.3.1.4Fill/Drain System
1.3.1.5 Propellant Feed
System
1.3.1.3 Pressurization
System
1.3.1.2 Thrusters
1.3.1.6 Instrumentation
1.3.1.1Tankage
1.3.1.1.2Propellant Tank
1.3.1.1.1Pressurant Tank
1.3.1.2.2 Reaction Control
Engine
1.3.1.2.1 Orbital
Maneuvering Engine
1.3.1.3.4Pressure
Regulators
1.3.1.4.1Fill/Drain Valves
1.3.1.4.2Filters
1.3.1.5.2Filters
1.3.1.5.1Latch Valves
1.3.1.5.3 Propellant Feed
Lines
1.3.1.6.2Temperature
Sensors
1.3.1.6.1 Pressure Sensors
1.3.1.3.3Filters
1.3.1.3.2Pyro Valves
1.3.1.3.1Latch Valves
1.3.1.3.5Pressurant Lines
1.3.1.1.2.1Propellant Tank
Structure
1.3.1.1.2.2Propellant
Management Device
1.3.1.4.3Fill/Drain Lines
1.3.1.2.3Engine Controllers
1.3.1.3.6Pressurization
Subsystem Valve Drivers
1.3.1.5.4Feed Subsystem
Valve Drivers
1.3.1.7Thermal Control
System
1.3.1.8Ancillary Hardware
1.3.1.7.1Active Thermal
Control
1.3.1.7.2Passive Thermal
Control
1.3.1.7.1.1Heaters
1.3.1.7.2.1Insulation/Blankets
1.3.1.8.1Power Distribution
& Harness
1.3.1.8.2Secondary Structure
Propulsion Subsystems (Level VI) Work Breakdown Structure (WBS)
Page 13
Recommendations
• Trade, trade, trade …. Then trade some more No “point design” No “show stoppers”
Technical, cost & schedule Challenge technical teams on “what – if’s”
• Manage stakeholder expectations & requirements “creep” Establish early, seek inputs
• Execute, execute… and execute Make decision !
Indecisiveness causes schedule delay, cost-over run with no accomplishments
Streamline Control Board Process Requirements & Change Management Latency
• Communicate, communicate, and more Keep the team informed Listen to the team (feedback)
Page 14
Technical Recommendations
• Minimize Technology Development in a Launch Vehicle Project Require component/ subsystem technology at TRL > 6
• Get decisions made between elements (Payload, LV, and Ground Systems) Lack of decision makers delay schedule & increase cost
• Allow technical teams to communicate Avoid “silos” mentality
• Do not manage by Spec and ICDs Manage by decision – making, not by documentation
• Design-to-Requirements, not Design-to-Performance Control technical metrics, affordability, and schedule
Page 15
Questions?