Air Force Flight Test Center

Transcription

1 Air Force Flight Test Center War-Winning Capabilities On Time, On Cost Aircraft Modifications at Edwards AFB May 2011 Approved for public release; distribution is unlimited. AFFTC-PA No.: Wayne Hale Instrumentation Division I n t e g r i t y - S e r v i c e - E x c e l l e n c e

2 Aircraft Modifications Mission Aircraft (T-2) Modifications Goals Challenges Capabilities Overcoming the Challenges Questions 2

3 Mission Our mission is to provide the Truth Data used for Test and Evaluation of aircraft at the AFFTC. This requires that we be the Center of Expertise for all aspects of Airborne Instrumentation. 3

4 Aircraft (T-2) Modifications From AFI Used to evaluate the technical performance, operational effectiveness, and/or the operational suitability of developmental hardware and software capabilities when not associated with a permanent modification. Used to install and operate T&E-specific support equipment, instrumentation and data recording equipment, telemetry systems, etc. on T&E assets. Used in support of all forms of T&E activity, including developmental test and evaluation, operational test and evaluation, and MAJCOMconducted force development evaluation activities. 4

5 Aircraft (T-2) Modifications From AFMCI Configuration changes that support research and development; design changes to existing T-2 modifications; and Developmental Test and Evaluation programs or in-service testing of systems or equipment Temporary hardware or software changes or alterations to aerospace vehicles (aircraft, guided weapons, drones, Remotely Piloted Vehicles (RPV), Unmanned Aerial Vehicle (UAV), and their associated ground stations, and missiles other than strategic), airborne support equipment, external and internal stores, subsystems, components, or support equipment which is governed by Technical Orders (T.O.) that interface with an aerospace vehicle Includes instrumentation modifications, but can also be temporary changes to prove, develop, or characterize future permanent modifications 5

6 Goals Develop Mission Support Processes that Enable us to: Meet Customer Requirements Cost, schedule, content Meet all safety requirements Comply with all regulations 6

7 Challenges Changing customer requirements and priorities Heavy workload Manpower limitations Budgets not in alignment with requested work Engineering and Fabrication/Installation are separate organizations Unable to merge organizations Numerous skill sets required to accomplish the mission Conflicting priorities Numerous regulations Short suspense projects with little up-front notice Aircraft not available to support design efforts 7

8 Challenges Lots of Engineering Data Lots of charge numbers Numerous T-2 Mod data packages and forms Large amounts of parts required New Challenge Air Force directive for independent airworthiness certification How does it affect our ability to execute modifications What T-2 modification regulations need to be re-written etc 8

9 Capabilities To understand the complexity of the organization and the challenges, we need to understand the capabilities and the different skills required to meet the mission Modification Management Modification Design Modification Installation 9

10 Capabilities Modification Management Gather requirements from customers Generate estimates for modification work Maintain Configuration Control Establish Theory Of Constraints project networks to track modification schedule Obtain modification approvals Brief project status to customers 10

11 Capabilities Modification Management 11

12 Capabilities Modification Design Provide inputs for cost and resource estimates and schedules Perform professional electrical and mechanical engineering services for unique R&D and prototype systems Create instrumentation system and installation designs for customers Oversee the installation of instrumentation system Document and archive design and analysis 12

13 Modification Design Capabilities 13

14 Capabilities Modification Design -Tensile Testing 14

15 Capabilities Modification Design PCB Lab 15

16 Capabilities Modification design - Diagnostics Diagnostics Laboratory RF Test and Evaluation Analog/Digital Diagnostics and Repair Acceptance Testing of Components 16

17 Capabilities Modification Design Hot Benches 17

18 Capabilities Modification Installation Highly skilled senior technicians (electronic and mechanical model makers) building and installing R&D and Prototype aircraft T-2 Mod equipment Provide inputs for cost and resource estimates and schedules Work with engineering to establish system/installation designs Work with maintenance to remove production components and systems Install mechanical and electrical components Execute acceptance testing of system Assist maintenance in aircraft reassembly 18

19 Capabilities Modification Installation Fabrication Shop 19

20 Capabilities Modification Installation Electrical Fabrication 20

21 Capabilities Modification Installation Aircraft Modification 21

22 Capabilities Modification Installation Stores Modification 22

23 Overcoming The Challenges To deal with the changing customer requirements, priorities, heavy workload, manpower limitations, and budgets not in alignment with requested work we implemented Theory of Constraints Project Management (TOCPM) in the Instrumentation Division This resulted in: More reliable customer commitment dates An understanding of our capacity to accomplish work When to schedule work A methodology to work the highest priority tasks first A detailed plan to work with the customer when schedule and budget were not in alignment with their needs 23

24 Overcoming The Challenges TOC PM Tools - Planning Identification of tasks, task dependencies, skill sets, and task times 24

25 Overcoming The Challenges TOC PM Tools - Planning Tasks are well defined how do you know when you are done? 25

26 Overcoming The Challenges TOC PM Tools Scheduling Critical Chain is identified and buffers are inserted 26

27 Overcoming The Challenges TOC PM Tools Scheduling Staggering of projects after synchronization 27

28 Overcoming The Challenges TOC PM Tools Execution Tasks sorted by priority based on highest priority 28

29 Overcoming The Challenges TOC PM Tools Execution 29

30 Overcoming The Challenges To deal with issues associated with Engineering and Fabrication/Installation being separate organizations we Matrixed key skill-sets from Maintenance to Engineering Created a single pay pool for both Maintenance and Engineering This resulted in One set of priorities Much improved working relationships Enhances the ability to accomplish concurrent engineering and fabrication/installation Supplemented engineering capabilities Highly skilled mechanical fabricators building parts to later be analyzed and documented by engineering and drafting Highly skilled electronic technicians who have the capability to review and provide input on electrical designs 30

31 Overcoming The Challenges Engineering Modification Branch Modification Mgt Section T-2 Mod Managers T-2 Mod Office T-2 Mod Regulations Configuration Control Engineering Design Section Mechanical Engineers Electrical Engineers PCB Designers Drafters/Designers Diagnostic Lab Analysis Engineering Documents MEA Engineering Installation Section Electronic Technicians Model Makers Dock Chiefs Mechanical Fab Shop Electrical Fab Shop Tool Control Hangar Chief Maintenance 31

32 Overcoming The Challenges To deal with the numerous regulations, short suspense projects with little up-front notice, and aircraft not available to support design efforts we Became experts in all the regulations and processes Developed local Test Wing Level regulations with built-in streamlined processes: Mod Notes (MN), Quick Reaction Mods (QRMs), and Concurrent Engineering Mods (CEM) This enabled us to Complete very small changes with MNs, and low risk short suspense mods with QRMs Have a safe way to accomplish larger mods in increments where access to the aircraft is required to complete design, but was not available, by using the CEM process 32

33 Overcoming The Challenges Comprehensive Test Wing process with safety as a priority Test Objectives Modification Requirements Conceptual Design Cost & Schedule Estimate Fly Mission Merged Under Quick Reaction Mod or Concurrent Engineering Mod Approval To Proceed Install & Test Buy Parts, Fabricate, & Kit Detail Design Final Documentation Final CCB Approval & Pre-Dock Mtg DRB Mtg (Design Approval) DRB Mtg (Prel CCB Approval) CCB members: AFFTC Safety Office, MX, Contracting, QA, and MEA 33

34 Overcoming The Challenges To deal with the engineering data, charge numbers, the numerous T-2 Mod data packages and forms, and the large amounts of parts required, the Instrumentation Management Information System (IMIS) was developed This provided a single website that provides Access to charge numbers and reports T-2 Mod Package form development Engineering data repository and configuration control Parts Database Work order submittals 34

35 Overcoming The Challenges 35

36 Overcoming The Challenges To address the changes/impacts to T-2 modifications and regulation re-writes driven by the requirements for independent airworthiness certifications we are: Meeting within our organization and other organizations at the AFFTC to develop a plan Meeting with our sister organizations within AFMC with the same or similar challenges to ensure our plan is consistent with their needs Teaming with the owners of the regulations and other AFMC organizations to ensure the regulation re-writes are compliant with the new requirements while still allowing us to execute T-2 modifications safely and effectively 36

37 Questions 37