Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08. Reliability Growth of Mobile Gun System during PVT Dmitry E. Tananko, Ph.D.,Reliability and Robust Engineering, GDLS Sharad Kumar, Senior Director, System Engineering, GDLS John Paulson, Director, Stryker Program, GDLS Jenny Chang, PM SBCT, TACOM LTC David J. Rohall, PM SBCT, TACOM James Ruma, VP, Engineering Programs, GDLS
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Reliability Growth of Mobile Gun System during PVT
Dmitry E. Tananko, Ph.D.,Reliability and Robust Engineering, GDLS Sharad Kumar, Senior Director, System Engineering, GDLS
John Paulson, Director, Stryker Program, GDLSJenny Chang, PM SBCT, TACOM
LTC David J. Rohall, PM SBCT, TACOMJames Ruma, VP, Engineering Programs, GDLS
2
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
3
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
AgendaWhat is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
4
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Mobile Gun System (MGS) 27Mobile Gun System (MGS) 27
5
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Mobile Gun System – The Bunker Buster
6
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
BLUF – Key Factors for Successful Reliability Growth Program
Program Management – Integrated TeamThe systems, tools, and practices now in place between the US Government and General Dynamics Land Systems allowed the system’s reliability to grow (repeatable process)Reliability growth requires commitments from Material Developer Team, Combat Developer, and Independent Test and Evaluation Communities (requirements, test, data, methodology, tools)
System Engineering – Reliability BackboneIntegrates All Reliability TasksRedirects Tasks Toward a Single ObjectiveCrosses Boundaries Affecting Operational ReliabilityProvides Program Manager Authority, Funding, and Focus on Engineering, Processes, Documentation, Training, Manufacturing, and Testing for Reliability
Inherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
7
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
8
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
MGS Program Management
Phase I - Conduct an Additional Reliability Test (ART)
Validate effectiveness of 216 PQT and Post-PQT corrective actions
Phase II - Implement changes to Government and GDLS Systems Engineering Processes
Management and process changes
Phase III - Redesign of Sub-System components and integration
Additional Reliability Testing (DEC 2004 – MAR 2005)
2 vehiclesPre-ART – XXX rounds & X00 milesART – XXX rounds & X,000 milesReliability Point Estimate XX MRBSA
Reliability Growth Test (JUL-AUG 2005)2 VehiclesXXX roundsX,000 milesReliability Point Estimate XX MRBSA
Production Verification Testing (APR 2006 - DEC 2007)
3 VehiclesXXXX roundsXX,000 milesOn-going – Current estimate XXX MRBSA
Plan Tests
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
AgendaWhat is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
11
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Stryker – Mobile Gun SystemFailure Prevention and Resolution Implementation
FPRB SteeringCommittee
Weekly
FPRBDaily
Corrective Action
2X per Week
PVT Retrofit Review
2X per Week
Quality Committee
2X per Week
Failure Analysis2X per Week
Prevention & Systemic
Issue Committee
Weekly
HYDRAULICLEAK
FOCUS TEAM
HARNESS &ELECTRICALFOCUS TEAM
ISSUES
ISSUES
ISSUES
ISSUES
CA Design Oversight
STATUS
STATUS
STATUS
STATUS
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONS / APPROVAL
STA
TUS
ISSU
ES
DEC
ISIO
NS
DEC
ISIO
NS
STATUS
LRU &SIGHTS
FOCUS TEAMADDITIONAL
TEAMSAS REQ’D
INDEPENDENT(MUNRO)
FOCUS TEAM
Reliability Assessments
and PredictionsSTATUS
External Experts
15
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
16
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Reliability Data Analysis
Proper Reliability Assessment is a key for the program success at PVTReliability Assessment must be discussed up front and consensus should be reached on:
Inherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
17
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
FDSC – Failure Definition Scoring Criteria
FDSC is Contractual Document that definesFailure/non-Failure EventTest related Event Severity of Failure as it relates to the MissionCause of the Failure
FDSC is prepared as required by Army Regulation 70-1, Army Acquisition Policy.FDSC is being used through out the test for Scoring purposes, hence it is a major document for Reliability Assessment
18
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Failure Categories
Performance FM – FM is repeatable with 100% probability of failure for the given procedure/conditions. (Example: TDS overheating) Software FM – same as above, but software related.Quality FM – happens when vehicle is not built/maintained/operated as designed and is not repeatable after fixing (probability of failure =0%). Can be broken down into Initial Quality, Maintenance, Operator error, etc. (Example: Improperly installed harness, turret lock bended, etc.)Potential Reliability FM – happens when vehicle was built/maintained/operated as designed/intended; probability of failure is greater than 0% and less than 100%; usually happens due to wear out, environment, insufficient design, manufacturingvariability, etc.
19
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Failure Mode Categorization ProcessInherent vs. Induced Failure
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Categorize Failures and take Relevant Management Actions
Failure Chargeability
Human26%
Performance43%
Quality7%
Reliability24%
HumanPerformanceQualityReliability
Training and ManualsDesign SimplificationsManagement of Maintenance Actions
Root Cause AnalysisDesign CorrectionsSelective Redesigns
Supplier Quality Management
21
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Data GroupingKnown Equivalent Time Unknown Equivalent Time
Miles
Roun
ds
Actual Mission Profile Run
OMS / MP
AEC Grouping
Miles
Rou
nds
0
Instantaneous MRBSA vs Rounds
Rounds
Inst
anta
neou
s M
RB
SA
Crow (NHPP)
Beta=0.5945
Inst
anta
neou
s M
RB
SA
0
Instantaneous Failure Intensity vs. Rounds
Rounds
Inst
ant.
Failu
re In
tens
ity
Crow (NHPP)
Beta=0.5827
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Rounds and Miles Accumulation per Vehicle vs. Calendar Time
UET model takes into account any discrepancies between different vehicles following through the test in calendar time
KET Model can be useful in the beginning of the test when vehicles have not accumulated enough mileage and rounds.
Cum Miles vs Calendar Time
Calendar Time
Cum
Mile
s
Cum Rounds vs Calendar Time
Calendar Time
Cum
Rou
nds
23
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Crow/AMSAA Model
Cum Number of Failures
Cum Failure Rate
Cum MTBF
Inst Failure Rate
Inst MTBF
βλ TNE ⋅=)(
1)( −⋅== βλ TTNErc
( ) ( ) 111 −−− ⋅== βλ TrMTBF cc
( ) 1))(( −⋅⋅=⋅
== ββ
βλλ tdt
tddt
NEdri
( ) ( ) 111 −−− ⋅⋅== ββλ TrMTBF ii
0
ReliaSoft's RGA 6 PRO - RGA.ReliaSoft.com
Cumulative Number of Failures vs Rounds
Rounds
Cum
. Num
ber o
f Fai
lure
s
Crow (NHPP)
Beta=0.5827
24
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Cumulative vs. Instantaneous Reliability
Reliability growth on the Development test is the result of Corrective Actions.Estimating Reliability of the product by taking the Cumulative reliability (total number of failures / total time on the test) does not take into account the growth on the test.
25
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Idealized Growth Curve and Observed Parametric Curve for Demonstrated Instantaneous MRBSA
Cu m Ro u n d s
Inst
. MR
BSA
Milestone 3
S C1 S C2 S C3 S C4 S C5/5a S C6 S C7 S C8 S C9
26
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
27
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
DFR Process Elements
Boundary Diagram / System Block Boundary Diagram / System Block DiagramDiagramInterface matrixPP--DiagramDiagramDFMEADFMEAReliability & Robustness MetricsDVP&RDVP&RReliability Demonstration MetricsReliability Demonstration Metrics
28
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
DFSS (DCOV) Flow of Analysis & Tools
Signifies the OPTIMUM S/N Set point…Signifies the OPTIMUM S/N Set point…
Function ModelingConcept Generation
& Selection
DoERobust Design & Tolerance Design
Functions
VOC KJ QFD
Customer Needs/Statements
Customer Requirements
FMEA
Technical Requirements
Reliability/Robustness Demonstration
0.1 1.0 10.0 100.0
1
2
3
5
10
20
30 40 50 60 70 80 90 95
99
Time to Failure
Per
cent
Probability Plot for time5Weibull Distribution-95.0% Conf idence Interv als
Censoring Column in censor5
ShapeScale
MeanStDev
MedianIQR
1.2257 7.8398
7.3357 6.0165
5.8135 7.3970
0.1 1.0 10.0 100.0
1
2
3
5
10
20
30 40 50 60 70 80 90 95
99
Time to Failure
Per
cent
Probability Plot for time5Weibull Distribution-95.0% Conf idence Interv als
Censoring Column in censor5
ShapeScale
MeanStDev
MedianIQR
1.2257 7.8398
7.3357 6.0165
5.8135 7.3970
Concepts
D
C
O
V
Boundary Diagram
P-DiagramDFMEA
Reliability & Robustness MetricsReliability
Demonstration
29
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Design For Reliability Map
30
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Continuing the effort to ensure MGS reliability growth
• Systems Engineering Process continues to be worked “24/7”
• GDLS Senior Leadership briefed on a daily basis
• Focus on implementation of Corrective actions on both the Test Vehicles and the Fielded vehicles
• GDLS teams at our vendors to work failure analysis and ensure MGS gets their top priority
• Outside experts on reliability and quality regularly review our processes in engineering and Manufacturing so we keep getting better
Continuing the effort to ensure MGS reliability growth
• Systems Engineering Process continues to be worked “24/7”
• GDLS Senior Leadership briefed on a daily basis
• Focus on implementation of Corrective actions on both the Test Vehicles and the Fielded vehicles
• GDLS teams at our vendors to work failure analysis and ensure MGS gets their top priority
• Outside experts on reliability and quality regularly review our processes in engineering and Manufacturing so we keep getting better
• Failure Rate continues to decrease, thus demonstrating substantial reliability growth in PVT
• Sustained decrease of MGS Failure Rate suggests infant mortality region is passed and design is maturing
• Failure Rate continues to decrease, thus demonstrating substantial reliability growth in PVT
• Sustained decrease of MGS Failure Rate suggests infant mortality region is passed and design is maturing
• Demonstrated Instantaneous MRBSA for decision-makers
• Growth Rate is 0.4
• RGA Methodology was developed and agreed by RAM-T Community
• Demonstrated Instantaneous MRBSA for decision-makers
• Growth Rate is 0.4
• RGA Methodology was developed and agreed by RAM-T Community
0
ReliaSoft's RGA 6 PRO - RGA.ReliaSoft.com
Instantaneous Failure Intensity vs.Rounds
Rounds
Inst
ant.
Failu
re In
tens
ity
Crow (NHPP)
Beta=0.5945
Rounds
31
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Keys to Success
Program Management forms Integrated Team (Material Developers, Tester/Evaluators, User) that has clear priority and focus on Reliability with clear understanding of Evaluation Criteria and Test Methods up front.
System Engineering assembles Reliability tools into Disciplined processes and Working Organizations
Reliability Assessment is reached through in-depth analysis and consensus between all involved parties
Program Management + System Engineering + Reliability = Success
32
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Questions and Discussion
33
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
34
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Dmitry Tananko, Ph.D.General Dynamics Land SystemsTel.: (586) 634-5071E-mail: [email protected]