Concurrent Engineering at ESA: from the Concurrent Design Facility (CDF) to a Distributed Virtual Facility

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Hannah Cox
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1 CE2007 The 14 th ISPE International Conference on Concurrent Engineering Sao Jose dos Campos, SP, Brazil, July 2007 Concurrent Engineering at ESA: from the Concurrent Design Facility (CDF) to a Distributed Virtual Facility Massimo Bandecchi Head of Concurrent Engineering section & Concurrent Design Facility (CDF) ESA/ESTEC Noordwijk (NL) CE Brazil, 18 July 2007 CE at ESA - 1

2 ESA: Europe in Space Austria Ireland Sweden The European Space Agency was established in 1975 Belgium Denmark Italy Luxemburg Switzerland UK ESA replaced the former Eldo launcher and Esro satellite organisations, grouping the complete range of civilian space activities in a single agency Esro Satellites Eldo Launchers Finland Netherlands France Norway Germany Portugal Luxemburg (16) and Greece (17) joined in 2004 Greece Spain Cooperation arrangement: Canada CE Brazil, 18 July 2007 CE at ESA - 2

3 ESA Establishments Noordwijk, The Netherlands ESTEC (European Space Research and Technology Centre) Project management, testing of spacecraft, development of new technologies, space science Staff: 1014 Paris, France Head Office Incl. offices in Brussels, Toulouse, Kourou, Moscow, Washington, Houston Staff: 348 Kourou, French Guiana CSG Europe s Spaceport for Ariane launches Cologne, Germany EAC (European Astronaut Centre) Astronaut training Staff: 19 Darmstadt, Germany ESOC (European Space Operations Centre) Satellite operations Staff: 222 Frascati, Italy ESRIN Earth Observation, Data Processing and Distribution Staff: 136 CE Brazil, 18 July 2007 CE at ESA - 3

4 What is a spacecraft system? (Mars Express) Harness Thermal control Telecommunications Electrical power Payload Data handling AOCS Structure Propulsion Mechanisms CE Brazil, 18 July 2007 CE at ESA - 4

& test Special needs No mass production (EM & FM) No field service

5 Space mission life cycle Design and development Technology development Component procurement Manufacturing Assembly Verification & test Special needs No mass production (EM & FM) No field service possible! Redundancy Launch Operations CE Brazil, 18 July 2007 CE at ESA - 5

6 ESA project life-cycle I n d u s t r y Phase A Phase B Phase C/D. E S A Pre- Ph. A SPEC. s Review SPEC. s Review SPEC. s CDR Launch. FDIR 10 5 years in CE Brazil, 18 July 2007 CE at ESA - 6

7 CE: a definition Concurrent* Engineering is a systematic approach to integrated product development that emphasises the response to customer expectations. It embodies team values of cooperation, trust and sharing, in such a manner that decision making is by consensus, involving all perspectives in parallel, from the beginning of the product life-cycle. * collaborative co-operative collective simultaneous. CE Brazil, 18 July 2007 CE at ESA - 7

8 CDF: what is it? The ESTEC Concurrent Design Facility is an Integrated Design Environment (IDE) available to all ESA programmes for interdisciplinary and interdirectorate applications, based on Concurrent Engineering methodology Following the experience of using CE for the assessment of specific mission, the implementation of a permanent facility started in Nov.1998, on an experimental basis on initiative (and support) of the General Studies Programme (GSP) initially conceived for the assessment and the conceptual design of future space missions, i.e. internal pre-phase A / feasibility studies featuring: team orientated concurrent engineering integration of tools, project data, mission and system models simultaneous participation of all mission domains, incl. Programmatics/AIV, Operations, Cost Engineering, Risk Analysis, CAD, Simulation CE Brazil, 18 July 2007 CE at ESA - 8

9 CDF: the achievements Activities performed 70+ (potential) future missions studied and designed internally at pre- Phase A, conceptual, system level 3 new launcher concept design 6 complex payload instrument design (IDA), incl. Platform, system, mission 12 reviews of Industrial Phase A studies (internal + Industry) 5 ISS on-board facilities/experiments accommodation studies; teaming with/supporting Industry in Phase A Joint studies with NASA/JPL/PDC-Team X (Distributed Concurrent Engineering), CNES CIC, Industry, Academia Anomaly investigation for later project phases Educational, training, promotion and standardisation activities Spin-off Transfer of CDF know-how and software to national Agencies, Industry, Academia CE Brazil, 18 July 2007 CE at ESA - 9

10 Design of manned vehicles for the exploration preparation programme Human Missions to Mars Moon Lander CE Brazil, 18 July 2007 CE at ESA - 10

11 Advanced launchers Socrates Heavy Lift Launch Vehicle CE Brazil, 18 July 2007 CE at ESA - 11

12 Telescopes and Technology FIRI WiFLY WFI Payload cutaway CE Brazil, 18 July 2007 CE at ESA - 12

13 The ESA project life-cycle = CDF application I n d u s t r y Phase A Evolving Applications Phase B Phase C/D. E S A Pre- Ph. A Launch. SPEC. s Review SPEC. s Review SPEC. s CDR FDIR Lessons Learned CE Brazil, 18 July 2007 CE at ESA - 13

14 CDF: the 5 key elements a process a multi-disciplinary team a facility an integrated design model a software and hardware infrastructure CE Brazil, 18 July 2007 CE at ESA - 14

15 CDF: the approach (Organisation dependent) Re-organization of existing tools and human resources in a more effective (i.e. concurrent ) way Technical Domains Engineering Tools & DB s Domain Specialists Interfacing Group System Perspective Data Sharing Team Engineers Integrated Design Environment CE Brazil, 18 July 2007 CE at ESA - 15

16 Design process Mission requirements & constraints Objectives Environment Lifetime Payload Reliability Schedule Technology Budget Study requirements Products Study Level Planning Resources Attitude determination & control Mission analysis Propellant mass Thermal control Propulsion Instruments Electrical power Structure Software Adapter Dry mass Data handling Wet mass Telemetry tracking & command Operations & ground systems Launch mass Study results S/C Design S/C Configuration Launcher Risk Cost Simulation Programmatics Options Conceptual model of mission & spacecraft design process CE Brazil, 18 July 2007 CE at ESA - 16

17 CE: iterative process The Spiral Model Mission analysis Sub-system design Mission requirements analysis Design verification Cost analysis Risk assessment CE Brazil, 18 July 2007 CE at ESA - 17

18 Integrated Design Model Domain Specific Tools & DBs Large Data Structures Subsystem-1 Programmatics Data Exchange Data (scalars) Parking (matrices) Risk Cost Subsystem-n System Presentation Sheets Calculation Sheets Outputs Sheet Inputs Sheet CE Brazil, 18 July 2007 CE at ESA - 18

19 CDF layout MULTIMEDIA WALL Doc. n Systems Config. Structure Customer and Ad-Hoc Experts Customer and Ad-Hoc Experts Team Leader Cost Risks Progr. s Simulation Mechanisms Instruments AOCS Thermal Propulsion Mission GS & Ops Comms DHS Power ESTEC Dh015 CE Brazil, 18 July 2007 CE at ESA - 19

20 A CDF design session CE Brazil, 18 July 2007 CE at ESA - 20

21 Conducted in sessions Process elements plenary meeting where representatives of all space engineering domains participate from early phases (requirement analysis) to end of design (costing) 6 to 10 session / study, 4 hour / session, bi-weekly frequency team leader co-ordination customer participation Model driven On-line design Highly co-operative & interactive Iterations Design options comparison and trade-offs CE Brazil, 18 July 2007 CE at ESA - 21

22 Space mission feasibility Technical Risk Programmatics Cost CE Brazil, 18 July 2007 CE at ESA - 22

23 Benefits Performances (typical pre-phase A study): Study duration (Design phase): 3-6 weeks (cp. 6-9 months!) Factor 4 reduction in time Factor 2 reduction in cost (for the Customer) Increased nr of studies per year, compatibly with max 2 parallel studies Improvement in quality, providing quick, consistent and complete mission design, incl. technical feasibility, programmatics, risk, cost Technical report becomes part of the specs for subsequent industrial activity, Cost report remains the ESA independent reference Capitalisation of corporate knowledge for further reusability CDF: an essential tool for the ESA Decision Making and Risk Management processes CE Brazil, 18 July 2007 CE at ESA - 23

24 Concurrent design centres for space in the world Facility name since > NASA:! NASA/JPL PDC (Project Design Center) 1996! Every NASA site is (getting) equipped with a CE facility! NASA/JPL Mission System Design Center 2000 > US Aerospace industries:! Aerospace Corp. (US) CDC (Concept Design Center) 1995! Lockheed Martin (US) CEE.! TRW. > European Space Agencies and Industries:! EADS ASTRIUM SDO (Satellite Design Office (D)) 1999! CNES CIC 2005! ASI CEF 2007! DLR CDF 2008 > Australia:! Victorian Space Science Education Centre 2005 CE Brazil, 18 July 2007 CE at ESA - 24

25 ESA partners using CDF Core-IDM CE Brazil, 18 July 2007 CE at ESA - 25

26 CNES CIC CE Brazil, 18 July 2007 CE at ESA - 26

27 EADS ASTRIUM (D) - SDO (Satellite Design Office) CE Brazil, 18 July 2007 CE at ESA - 27

28 Alenia (Turin) - CDF Multimedia devices Layout Software s development laboratory Concurrent Facility CE Brazil, 18 July 2007 CE at ESA - 28

29 New CDF September 2007 CE Brazil, 18 July 2007 CE at ESA - 29

30 Enabling Factors Our lesson learned (some hints) Convince the parties involved; each one should get added value(s) from the new approach: Specialist engineers (involvement end-to-end) Management (business case, ROI) Customer (provide a better driver s seat ) Computer and model based (or aided) design: not necessarily a complicated ICT infrastructure Parametric design model No radical change in tools and data, to start with, but concentrate on new approach, creation of the team Right at the first time (especially for space ) Standardised flexibility or flexible standard (part of the systematic approach, i.e. the references) Radical change in mentality and attitude required from all stakeholders CE Brazil, 18 July 2007 CE at ESA - 30

31 Integrated Design Model Domain Specific Tools & DBs Large Data Structures Subsystem-1 Programmatics Data Exchange Data (scalars) Parking (matrices) Risk Cost Subsystem-n System Presentation Sheets Calculation Sheets Outputs Sheet Inputs Sheet CE Brazil, 18 July 2007 CE at ESA - 31

32 The steps to the Distributed Virtual Facility Promotion of concurrent design methods among the European partners, Industry and Academia Standardisation of the Data Model derived from the CDF Integrated Design Model - creation of a product IDM based on open standards, but only the core part of it Distribution of the product IDM (core) to European space industry and partners as Community Software Assessment of the GRID technology and infrastructure as the enabler for the creation of Distributed Concurrent Design and a Virtual Concurrent Facility Assessment of expansion of CE technologies over all project-phases CE Brazil, 18 July 2007 CE at ESA - 32

33 The vision CE Brazil, 18 July 2007 CE at ESA - 33

34 Further information provided on CDF Web site: CE Brazil, 18 July 2007 CE at ESA - 34

Der virtuelle Entwurfsprozess (Virtual Spacecraft Design VSD)

Der virtuelle Entwurfsprozess (Virtual Spacecraft Design VSD) Joachim Fuchs (joachim.fuchs@esa.int) Modelling and Simulation Section (TEC-SWM), Software and Technology Dept. Technical Directorate, ESA