BAE SYSTEMS Example of Applied Systems Engineering at BAE SYSTEMS & ALENIA MARCONI SYSTEMS 5/19/2015/MS By Keith Minnican Friday 27th July 2001

BAE SYSTEMS Customer Requirements In-Service Support Requirements Analysis Acceptance Trials System Specifications Test & Commissioning by System Structured Sub-System Specifications Manufacture & Assembly by Area/Zone Acceptance Criteria Configuration & Change Control What the Customer Wanted System Co-ordination Procurement Long Lead - Vendor Agreements - Call Offs Sub-System Design Integration by Area/Zone Historical Product Development Life-Cycle: Systems View

BAE SYSTEMS Historically: Stand-Alone Sequential Processes Are they finished yet? When will we get the drawings? Is there anybody listening? Is there anybody there?

BAE SYSTEMS The Old Shipyard Way: “Over the Wall ” Information was not effectively shared, resulting in physical rework Market pressures forced reduced Design & Build Timescales Understanding what’s gone before Inefficiency during transfer of knowledge and understanding Iterations

BAE SYSTEMS Organisation Programme Based – Prime Contract Organisation – Fixed Price – Multi-disciplined Design and Build Teams – Concurrent Engineering – Shared Data environment across all sites – Design and Build Engineering Directorate – Design support to programmes – Development of Processes and Systems – Resource development and deployment – External Design related Contracts – Research and Design Related activities

BAE SYSTEMS Product Definition Stage 1 Procurement Long-Lead Items -- Vendor Agreements -- Call-Offs -- Spares Initial Design Concept Feasibility System Design Sub-system Design & Primitive Modelling Stage 2 Spatial Integration & Detail Modelling Engineering Outputs to Production Installation & Outfit Test & Commission Parts Manufacture In-Service Support Disposal Stage 3Stage 4Stage 5Stage 6Stage 7Stage 8 Safety & Hazard Logs; Connection Details; Test & Commissioning Documents; Support, Reliability & Maintenance Records; Technical Manuals; Datum Pack; Trouble Reports; etc Stage 0 Product Development Life-Cycle BAE SYSTEMS Marine Ltd Tollgate KEY

BAE SYSTEMS ACCEPTANCE START Provide Specialist Support (ARM, Safety, Operations, ILS Etc) Manage Systems Engineering Support Higher level Tests (trials) Secure Acceptance and Certification (Stage 0)(Stage 1, 2 & 3) SUB SYSTEM ENGINEERING AND IMPLEMENTATION Determine Requirements (Stage 4)(Stage 5 & 6) Design System And specify/procure Sub Systems Create Candidate Solution Concepts Perform Functional Analysis Integrate and Test System Harmonise Sub System Implementations Perform System Analysis ISS ELECTRONIC DATUM PACK MANAGEMENT SERVICE MAINTENANCE MANAGEMENT SERVICE STOCK MANAGEMENT SERVICE DESIGN CHANGE/UPGRADE MANAGEMENT SERVICE (Stage 7) LIFECYCLE COSTING MANAGEMENT SERVICE PROVISIONING MANAGEMENT SERVICE DESIGN for SUPPORT MANAGEMENT SERVICE Engineering Process Model - LM05/05

BAE SYSTEMS Stage 0: Product Development Life-Cycle Definition Business Response Market request External Customer request Internal Customer request Internal R&T opportunity 0a Entry 0b Conceptual Design and Validation 0c Risk Assessment REVIEWS SYSTEMS REQUIREMENTS FUNCTIONAL DESIGN SYSTEM DESIGN BID DESIGN D Checklists: Maturity statements Summary Sheets Documented evidence Requirements & Acceptance Systems Engineering Whole Ship Integration & Systems Interfaces Technical Parameter Management Structure Build Strategy & Operations Procurement & Development Items Risk Register Resources Information Technology & Management Metrics & Management Processes Change & Configuration Management Technical Programmes & Timescales Stage 0

BAE SYSTEMS a Entry 1b System Design & Primitive Modelling 1c Iteration/Exit Whole Ship Integration SYSTEM A SYSTEM B SYSTEM C SYSTEM D SYSTEM E SYSTEM F SYSTEM G Systems Engineering Functional Definition Equipment Specification Structural Design System Design and Approval Technical Parameter Modelling Primitive Modelling & Integration Major equipment, Major pipework & pipebanks Major cableways Ventilation trunking Lifting eyeplates/removal routes Assualt, store and escape routes Maintenance envelopes Major seats Shock mounted equipment Minor bulkheads Walkways Equipment Physical Data Safety Case Integration Support Production and Commissioning Support Stage 1 Stage 1: Product Development Life-Cycle Supplier Information Functional Definition Strategies & Plans Design Procurement Assembly & Manufacture Support Stage 0

BAE SYSTEMS Stage 1: Sub-System Design & Primitive Modelling

BAE SYSTEMS a Entry 3b Produce Outputs Whole Ship Integration ZONE A ZONE B ZONE C ZONE D ZONE E ZONE F ZONE G ZONE A ZONE B ZONE C ZONE D ZONE E ZONE F ZONE G FABRICATION/NAS DDH SMITE SHEET METAL/SHOPS OUTFIT SLIPWAYS 2a Entry 2b Spatial Integration & Modelling Detail 2c Iteration/Exit 1 0 Modelling Strategy Preferred/np/non-standard Procurement Outfit/Build Plan Modularisation Production Outputs Support Integration By Area Stage 2 & 3: Product Development Life-cycle Stage 1Stage 2

BAE SYSTEMS Stage 2: Integration by Area (Space and Level of Detail)

BAE SYSTEMS Stage 3: Outputs to Production Exploded View of Unit 306 Steelwork

BAE SYSTEMS Create Design / Physical Part Link to Items Database (Allocate Part Nos. to Piece Parts ) MSO Create IGES Files Create Weld Database Firm Plan Manufacture & Assembly Release to CC Create Workstation Drawings Compass Contract Add Lead Time Offsets Stage 3 into Stage 4: Manufacture and Assembly Release

BAE SYSTEMS Product Definition Stage 1 Procurement Long-Lead Items -- Vendor Agreements -- Call-Offs -- Spares Initial Design Concept Feasibility System Design Sub-system Design & Primitive Modelling Stage 2 Spatial Integration & Detail Modelling Engineering Outputs to Production Installation & Outfit Test & Commission Parts Manufacture In-Service Support Disposal Stage 3Stage 4Stage 5Stage 6Stage 7Stage 8 Safety & Hazard Logs; Connection Details; Test & Commissioning Documents; Support, Reliability & Maintenance Records; Technical Manuals; Datum Pack; Trouble Reports; etc Stage 0 Stage 4 Determines Outputs in Stage 3 Stage 3 Determines Level of Detail in Stage 2 Stage 2 Determines Modelling Strategy for Stage 1 Product Development Life-cycle Dependencies Stage 0 Determined by Design & build re-use

BAE SYSTEMS Key Success Factors Satisfactory Design Validation of Stage 0 Build Strategy Detailed planning and integration Requirements Capture and Management Appropriate System Partitioning Functional Analysis Transverse requirement management Controlled Design Reviews Successful Tollgate entry and exit between all stages Facts Based trade-offs

BAE SYSTEMS Integrated Processes, Measures and Systems Processes & Best Practice Data & Systems Architecture Measures & Norms Working Towards ~ A Common Approach

BAE SYSTEMS Internal Customer Perceptions Processes –Global understanding –Ownership –Management –Effectiveness Measures Measures –Not uniformly applied –Unclear –Ownership

BAE SYSTEMS Internal Customer Perceptions Data –Understanding of Product Database –Data structures Complex –Data categorisation Systems Architecture –Ability to absorb –Extensive Support and training –What to use when

BAE SYSTEMS Internal Customer Perceptions Basics are sound (Stage 0, 1, 2 and 3) need to concentrate on ‘making it work’ and how best to apply and operate. –Education and Awareness –Ownership –Compliance Audits –Review & Refresh –Hierarchy –Touch & Feel

BAE SYSTEMS Form and Content: Touch and Feel Written in QA speak - not for Engineers –Documents seen as an ‘evil’- for audit only Process content of variable quality

BAE SYSTEMS Hull Structure Hull/Hull Mechanical Hull Outfit Removal Routes Seats/Mountings Penetrations Compartments GA Whole Ship Integration HVAC Electrical Piping Executive Summary Process Applications Training Manuals Standards & Conventions Best Practice Guides Best Practice Examples Worst Practice Examples Search Home Contacts Who to See Hints & Tips Help Office Assistant Measures & Norms Best Practice Proposed Documentation / Information Structure

BAE SYSTEMS

Processes Systems Measures Best Practice Hints & Tips Norms Common set of Processes, Measures & Systems Ownership of Processes, Measures & Systems with knowledge and area of expertise Check applicability and appropriateness ~ refresh Monitor compliance ~ usage and content Taking the Service Level Agreement that step further! Working Towards - A Common Book Approach

BAE SYSTEMS Working Towards - Common framework to support each Project (Taking the Service Level Agreement that step further) Processes Systems Measures Best Practice Hints & Tips Norms Processes & Best Practice Applications & CVmacs System & Data Architecture Measures Training Compliance Checks Change Request, Implementation & Management Customer Charter Common Framework Configuration Control

BAE SYSTEMS Any Questions? Questions