1. 1 Systems Approach To Effective Diagnostics & Prognostics 07/23/2003

2. 2 Our Company 28 YEARS of TECHNICAL SERVICE

3. 3 A Systems Engineering Approach to Integrated Diagnostics and Prognostics Requirements Derivation Requirements Flow down Design Development Design Optimization Embedded Systems Life Cycle Support

4. 4 ILS INTEGRATED LOGISTICS SUPORT RFP REQUEST FOR PROPOSAL SDP SOFTWARE DEVELOPMENT PLAN SEDS SYSTEMS ENGINEERING DETAILED SCHEDULE SEMP SYSTEMS ENGINEERING MANAGEMENT PLAN SEMS SYSTEMS ENGINEERING MASTER SCHEDULE T&E TEST AND EVALUATION URD USER REQUIERMENTS DOCUMENT A SPEC SYSTEM FUNCTIONAL REQUIREMENTS B SPEC ALLOCATED DEVELOPMENT REQUIREMENTS C SPEC PRODUCT FUNCTION/FABRICATION REQUIREMENTS D SPEC PROCESS REQUIREMENTS E SPEC MATERIAL REQUIRMENTS SSDD SYSTEM SEGMENT DESIGN DOCUMENT ICD INTERFACE CONTROL DOCUMENT TRS TEST REQUIREMENTS SPECIFICATION MGMT DIRECTION & REPORTING T&E PLANS SDP A/B SPECS C/D/E SPECS Product SEMP SEMS SEDS External Customer External Customer Project Mgr Systems Engineering Management Requirements And Architecture Definition Design, ILS Production & Test System Integration & Verification Project Mgr URD & Stakeholder Requirements RFP Contract Program Plan Cost Objectives Integrated and Qualified System SSDD ICD TRS Deployed System System Design Package Product Characteristics SI&V PLAN Staffing & Resource Requirements Technical Program Progress Reports Conceptual Design, Support and IR&D Trade Analyses Technology Refresh / Operational Analysis / Historical Maintenance Data & Analysis Conceptual / IR&D Requirements & ArchitecturalDefinition SE Management System Integration & Verification (SI&V) Verification (SI&V) Deployment& Fielded System Development

5. 5 Performance Risk Defined Performance Risk is Uncertainty in the ability of a design to meet the specified performance level and the consequences thereof The gap between the validated and specified performance levels and the consequences of that gap “Performance” is defined broadly to include Operability, Functionality, Safety, Testability, Affordability, Reliability, Availability, Maintainability, etc. Any dimension of value to the customer Validated Performance Level Specified Performance Level Gap

6. 6 Today’s Technology Provides Process Improvement To Fill the Gap Enhanced Diagnostics Modeling Provides: –Improved Fault Detection Confidence (FD%) –Improved Fault Isolation to Optimum Repair Level (FI%) –Reduced False Alarms / False Removals (FA%) –Lower Mean Time to Isolate (MTTI) –Improved Operational Availability (Ao) –Improved Safety Through Critical Fault Analysis (FMECA) –Reduced Life Cycle Cost

7. 7 Development Information Model Topology (Visualization) Functions (Objects + Nets) Failure Modes (FMECA) Test Definitions (Testing) Diagnostic Strategy Failure Effects (FMECA) FMECA Report Working on DMECA (Degraded Mode Effect and Criticality Analysis)

8. 8 Global Modeling Electrical Electronic Mechanical Hydraulic Optical Software Process Fully Hierarchical Object-Oriented Networked

9. 9 Diagnostic Outputs Light Green - partially proven good - not yet suspected Green- proven good Light Blue Stimuli necessary for test Yellow - suspected, in current suspect set Teal - secondary suspects, not in the current suspects set but could be responsible for a previously performed test that failed Dark Red - contains potentially failed components, in AG Light Red - higher level part for which a lower level part is color dark red Dark Blue -I/O Test Point Diagnostic Fault Tree Provides an interactive interface to “exercise” the diagnostics. Provides means to “check” models for validity. Quickly Identifies problem areas (i.e.. Large fault / ambiguity groups) Can be used for Intelligent troubleshooting

10. 10 FMECA Output

11. 11 Process Interoperability Testability / Diagnosability Reliability / Safety Maintainability Testability Updates Reliability Updates Maintainability Updates Topological Model Reliability Predictions Functional Allocation System Partitioning Part Selection Functional Modeling Test Definition Diagnostic Development Maintenance Planning Diagnostic Reports FMECA/Safety Analysis FMECA Reports FMECA Validation Maintenance Procedures Embedded Diagnostics & Prognostics Operation and Support Environment Prognostics & Failure Trend analysis Prognostics modeling

12. 12 Topological Model Design Topology – System, Subsystem, Component, etc. Graphical Layout of Objects Facilitates Design Visualization and Communication between Engineers, Logisticians, Management and Customers Graphical Layout of Objects Facilitates Design Visualization and Communication between Engineers, Logisticians, Management and Customers Schematic Information (Objects, Nets, etc.) Can Be Imported From External Engineering Tools (CAD/CAE, etc.) Schematic Information (Objects, Nets, etc.) Can Be Imported From External Engineering Tools (CAD/CAE, etc.) Basic Topological Model Consists of Objects, Ports, Nets and Functions (Connectivity and Functional Dependencies) Basic Topological Model Consists of Objects, Ports, Nets and Functions (Connectivity and Functional Dependencies) Hierarchical Systems Can Be Created by Linking Topological Models So That Upper-Level Requirements Flow Down (Top Down Design) or Lower-Level Details Roll Up (Bottom Up Design) Hierarchical Systems Can Be Created by Linking Topological Models So That Upper-Level Requirements Flow Down (Top Down Design) or Lower-Level Details Roll Up (Bottom Up Design) Return to Top Level Process

13. 13 Functional Allocations Functional Design Definition and Requirements Allocations Can Be Performed / Analyzed Before Actual Hardware is Selected Top-Level Functional Design Defines End-to-End Functional Design Requirements for the Entire System Top-Level Functional Design Defines End-to-End Functional Design Requirements for the Entire System Top Level Attributes (Reliability, Cost, Time) Can Be Imported From External Tools / Databases (LSA, Reliability, FMECA, etc.) Top Level Attributes (Reliability, Cost, Time) Can Be Imported From External Tools / Databases (LSA, Reliability, FMECA, etc.) Early Trade Studies Facilitate Allocation of System Operational and Maintenance Requirements (Testability, Reliability, Maintainability, etc.) among different Functions. Early Trade Studies Facilitate Allocation of System Operational and Maintenance Requirements (Testability, Reliability, Maintainability, etc.) among different Functions. Initial Gaps between Requirements & Design can be Identified Early Initial Gaps between Requirements & Design can be Identified Early First Level for Design Influence and Trade Studies First Level for Design Influence and Trade Studies Return to Top Level Process

14. 14 Maintenance Planning & Requirements Development Initial Maintenance Requirements Need to be Defined Early to Support Design Influence Design Needs to Fit Support Environment / Maintenance Goals Design Needs to Fit Support Environment / Maintenance Goals Turnaround Time / Mean Time to Repair / Availability Cost of Ownership / Life Cycle Cost Cost of Ownership / Life Cycle Cost Supply Chain Concept / Level of Repair Supply Chain Concept / Level of Repair Balance between Embedded Diagnostics / Support Equipment Balance between Automated Diagnostics / Technical Documentation & Training Balance between Automated Diagnostics / Technical Documentation & Training Resource Availability / Specialization (Personnel, Equipment, Facilities) Resource Availability / Specialization (Personnel, Equipment, Facilities) Maintenance Planning and Requirements Development is an Iterative Process and Must be Part of Design Development and Optimization Maintenance Planning and Requirements Development is an Iterative Process and Must be Part of Design Development and Optimization Return to Top Level Process

15. 15 System Partitioning System Partitioning is Final Iterative Step in Top Down Design Process Implements Functional Allocation Requirements Physical Design Partitioning Implements Functional Allocation Requirements Physical Design Partitioning Maps Functional Design to Physical Design Maps Functional Design to Physical Design Final Functional Design Approval Stage Prior to Components / Parts Selection Final Functional Design Approval Stage Prior to Components / Parts Selection Drives Requirements down to Subcontractors and COTS vendors Drives Requirements down to Subcontractors and COTS vendors Completes Process in Functional Trade Studies to Balance LCC against Acquisition Costs Completes Process in Functional Trade Studies to Balance LCC against Acquisition Costs Return to Top Level Process

16. 16 Parts Selection Starts Bottom Up Design and Implements Physical Design Part Selection Trades: Part Selection Trades: Reliability Reliability Testability (Critical for COTS BIT Criteria) Testability (Critical for COTS BIT Criteria) Performance Performance Cost (Make / Buy) Cost (Make / Buy) Detailed Attributes (Reliability, Cost, Time) Can Be Imported From External Tools / Databases (LSA, Reliability, FMECA, etc.) Detailed Attributes (Reliability, Cost, Time) Can Be Imported From External Tools / Databases (LSA, Reliability, FMECA, etc.) Parts Selection Process Sets the Design Characteristics for Diagnosibility and Maintenance Support Parts Selection Process Sets the Design Characteristics for Diagnosibility and Maintenance Support Return to Top Level Process

17. 17 Reliability Predictions Return to Top Level Process Failure Rate Predictions Begin at First Level of Bottoms Up Design Predictions Performed Outside of eXpress Tool and can be Exported to eXpress Predictions Performed Outside of eXpress Tool and can be Exported to eXpress Selected Parts Candidates Feed Reliability Analysis Selected Parts Candidates Feed Reliability Analysis Reliability Attributes Support Parts Selection, Fault Isolation Weighting, and Maintenance Planning Reliability Attributes Support Parts Selection, Fault Isolation Weighting, and Maintenance Planning System Reliability Studies can be based on Parts Reliability vs. Functional Redundancy and Remediation Capabilities Resulting from Diagnostic Development and Criticality / Safety Studies System Reliability Studies can be based on Parts Reliability vs. Functional Redundancy and Remediation Capabilities Resulting from Diagnostic Development and Criticality / Safety Studies

18. 18 FMECA / Safety Analysis Return to Top Level Process Establish Failure Modes, Effects and Criticality for Functional Components, Subsystems and System Functional Use of Parts, Reliability Data and Safety Requirements Drive FMECA Functional Use of Parts, Reliability Data and Safety Requirements Drive FMECA FMECA can be Developed Outside of eXpress and Exported to eXpress, or Developed inside of eXpress with its Integrated FMECA Capability FMECA can be Developed Outside of eXpress and Exported to eXpress, or Developed inside of eXpress with its Integrated FMECA Capability eXpress Developed FMECA can be Exported to FMECA Tool / Excel eXpress Developed FMECA can be Exported to FMECA Tool / Excel FMECA Drives Fault Detection and Fault Isolation Probability and Fault Group Size Requirements FMECA Drives Fault Detection and Fault Isolation Probability and Fault Group Size Requirements

19. 19 Functional Modeling Return to Top Level Process Defines Bottoms Up Design Functionality – System, Subsystem, Component, etc. Low Level Functional Description Low Level Functional Description Low Level Test Methodology Low Level Test Methodology Models Functional Dependencies Models Functional Dependencies Models Propagation of Behavior Models Propagation of Behavior Creates End-to-End Design Relationship Creates End-to-End Design Relationship Creates Functional Description with Failure Mode Overlay Creates Functional Description with Failure Mode Overlay Describe Degradation of Functions Describe Degradation of Functions Importable from Reliability Processes (incl. FMECA) Importable from Reliability Processes (incl. FMECA)

20. 20 Test Definition Return to Top Level Process Test Definitions are Modeled to Establish the Tests Expected in the Operational System Uses End-to-End Functional Dependencies Uses End-to-End Functional Dependencies Adds Abstract Knowledge Beyond what Functions Contain Adds Abstract Knowledge Beyond what Functions Contain Establishes the Base for Diagnostic Strategies Establishes the Base for Diagnostic Strategies Test Strategies are Traceable to FMECA Test Strategies are Traceable to FMECA

21. 21 Diagnostic Development Return to Top Level Process Defines the Strategies for Optimizing Probability of Fault Detection and Fault Isolation Orders Tests using Strategy Rule Orders Tests using Strategy Rule Creates Detection Order Creates Detection Order Creates Isolation Sequence for each Detection Test Creates Isolation Sequence for each Detection Test Establishes Ambiguity Groups Establishes Ambiguity Groups Produces Testability and Maintainability Statistics Produces Testability and Maintainability Statistics

22. 22 FMECA Reports Return to Top Level Process Displays FMECA Attributes Conforms to MIL-STD-1629 and SAE Required Information All Information Needed fo FMECA is Contained Within eXpress All Information Needed fo FMECA is Contained Within eXpress User can Add or Delete Fields to Meet Reporting Needs User can Add or Delete Fields to Meet Reporting Needs Excel Spread Sheet FMECA can be Generated Directly for eXpress Excel Spread Sheet FMECA can be Generated Directly for eXpress

23. 23 Diagnostic Reports Return to Top Level Process Generates Diagnostic Analysis Results Provides Information on eXpress Generated Diagnostics Attributes: Provides Information on eXpress Generated Diagnostics Attributes: Fault Detection Probability Fault Detection Probability Fault Isolation Probability Fault Isolation Probability Weighted Detection Weighted Detection Fault Group Size Allocations Fault Group Size Allocations Sensor Placement Sensor Placement Other Design Related Information Other Design Related Information Reports are used to Assess the Design and to Provide Reports are used to Assess the Design and to Provide

24. 24 FMECA / Diagnostics Validation Return to Top Level Process The FMECA Report Information is Used to Validate the Diagnostics Failure Modes are Defined to Ensure there is a Probability of Detecting the Failure Failure Modes are Defined to Ensure there is a Probability of Detecting the Failure Criticalities are Defined to Ensure Critical Failures have a high Probability of Detection Criticalities are Defined to Ensure Critical Failures have a high Probability of Detection Failure Effects are Defined to Ensure Fault Groups are Isolatable to Support On-Board Remediation and Ground Maintenance Failure Effects are Defined to Ensure Fault Groups are Isolatable to Support On-Board Remediation and Ground Maintenance

25. 25 Maintenance Procedures Return to Top Level Process eXpress Diagnostic Fault Tree Supports Intelligent Troubleshooting Provides Prioritized Test Sequences Provides Prioritized Test Sequences Can Interface with Class IV IETM to Provide Interactive Troubleshooting Can Interface with Class IV IETM to Provide Interactive Troubleshooting Can Interface with Platform Health Management Information to Provide Class V IETM Capability (Intelligent Integration with Operation Equipment) Can Interface with Platform Health Management Information to Provide Class V IETM Capability (Intelligent Integration with Operation Equipment) Reduces Skill Level and Training Requirements Reduces Skill Level and Training Requirements Reduces Maintenance Time Reduces Maintenance Time Reduces False Removals Reduces False Removals

26. 26 Prognostics Modeling Return to Top Level Process Effective Prognostics Requires Diagnostic Knowledge of System Prognostic Algorithms Need to be based on System Functionality, Failure Modes, and Criticality Prognostic Algorithms Need to be based on System Functionality, Failure Modes, and Criticality Efficient Diagnostics Modeling Provides Much of the Data Needed for Prognostics Modeling Efficient Diagnostics Modeling Provides Much of the Data Needed for Prognostics Modeling System Diagnostics Optimization Provides High Confidence for Prognostics Monitoring Points System Diagnostics Optimization Provides High Confidence for Prognostics Monitoring Points Effective Prognostics Requires History with Intelligent Data Tracking Effective Prognostics Requires History with Intelligent Data Tracking Initial Operations Require Diagnostics Models for Heath Management – Prognostics Must Learn Initial Operations Require Diagnostics Models for Heath Management – Prognostics Must Learn Prognostics is More Effective With Wear Factor Failures than with Electronics Prognostics is More Effective With Wear Factor Failures than with Electronics

27. 27 Embedded Diagnostics & Prognostics Operation and Support Environment Return to Top Level Process The Benefits of Effective Diagnostics and Prognostics Analysis and optimization Embedded Diagnostic Confidence is the Result of Verifiable Design Analysis and Optimization Embedded Diagnostic Confidence is the Result of Verifiable Design Analysis and Optimization Optimum Safety, A o, and Cost of Ownership is the Result of the Optimum Mix of Embedded Diagnostics and Prognostics Optimum Safety, A o, and Cost of Ownership is the Result of the Optimum Mix of Embedded Diagnostics and Prognostics An Optimized System is Balanced Between Embedded Diagnostics and Ground Support Diagnostics An Optimized System is Balanced Between Embedded Diagnostics and Ground Support Diagnostics Effective System Health Management Information Availability to the Support Environment Reduces TAT and Logistics Support Costs Effective System Health Management Information Availability to the Support Environment Reduces TAT and Logistics Support Costs

28. 28 Prognostics & Failure Trend Analysis Return to Top Level Process Intelligent Data Retrieval, Management, and Analysis is Required for Continual System Diagnostics and Prognostics Maturation Provides Functional Degradation Tracking for Prognostics Maturation Provides Functional Degradation Tracking for Prognostics Maturation Provides Failure Tracking for Reliability Trend Analysis Provides Failure Tracking for Reliability Trend Analysis Requires Robust Configuration Control Requires Robust Configuration Control Requires Mapping of System Operational Profile to Event Requires Mapping of System Operational Profile to Event Requires Embedded Diagnostics “Cooked” Data and Selected Raw Data Requires Embedded Diagnostics “Cooked” Data and Selected Raw Data

29. 29 Reliability Provides Data to Diagnostics Models Functional Dependency Failure Mode Rule Base Case Base Model Based Reasoner (MBR) AI Prognostic Typical Model Types Developed or Supported Design Direction Design Assessment Design Optimization Support to Ground Operations Higher Order Run Time Require Developed System Derive Information from Functional, Dependency and Failure Information Support to Optimization Studies

30. 30 Systems Process at Work RAH-66 Comanche Program Boeing-Sikorsky-US Army Diagnostic Design Requirements Analysis Guide (DDRAG) Note: Document contents are export restricted with distribution limited to US Government agencies For Distribution and questions, please contact: Steve Desantis Boeing 610-591-6558 stephen.f.desantis@boeing.com

31. 31 Systems Process at Work DDRAG Purpose Comanche Team Desktop Reference –Ensures Standard Processes and Procedures for All Levels of Diagnostics Design Development Identifies Processes Needed to Define Diagnostics Design Requirements –Equipment –Subsystems –System / Segment –Air Vehicle –External Diagnostics Defines Operational Flight Program and Off-Board Diagnostics Requirements

32. 32 Design Process management All Levels of Design Data and Tools Need to be Interoperable Tools Need to Support Open Information Architecture Process Needs to be Managed Through an Integrated Product Development Environment (IPDE) –A Concept Development System was Developed for NASA on the 2 nd Gen RLV / SLI Project to Meet the Interoperability Needs IVHM Systems Management Environment (ISME) –Data Management –Translation between Tools, Data and ISME –Version / Configuration Control –Audit Trail Management –User Control –Security KEEP EVERYONE ON SAME PAGE

33. 33 Important Enterprise Features TYX TestBase ® DSI eXpress™ TYX Test Requirements Document Embedded Diagnosis & Health Mgmt. Factory Test Field Test Interactive Electronic Technical Manual (IETM) Maintenance Data Collection Gateway Vehicle Ground Ops Depot/Vendor