Head, Aging Aircraft Program

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The Redesign Dilemma
Robert P. Ernst

• Head, Aging Aircraft Program
• Naval Air Systems Command

2
Agenda
Decision factors options for the program
manager
Weapons for fighting the impacts of Defense
Darwinism
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Program Managers Dilemma

• Redesign or Life-of-Type Support
• What factors need to be considered?
• What option does the PM choose?
• At what point does the PM decide?

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Replacement Decision Trigger
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Decision Factors

• Service Life
• Operational Requirements
• AVDLR or Maintenance Cost
• Hardware Availability
• Sustaining Support
• Available Options
• Associated Risk
• Cost of execution

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Decision Factors -Service Life
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Decision Factors -Service Life

• Hardware Wear out
• Drift rate of components
• Handling, excessive rework, fatigue, time vs
  gain, offsets, etc
• Reversion of Materials
• Adhesive or epoxy breakdown due to time, temp,
  sunlight

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Decision Factors-Operational Requirements
Enough Parts
Obsolescence
Good () Parts
?
Cost Reliability
Does the job
Functionality

• Need increased performance
• Mission Change
• Improperly defined Reqts

• High Failure Rate
• Electrical Stress
• Thermal Stress
• Mechanical Stress

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Decision Factors Hardware Availability

• Integrate supply demand
• Evaluate system-level spares
• Excess microcircuit stock/die

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Decision Factors Hardware Availability

• Integrate supply demand
• Evaluate system-level spares
• Excess microcircuit stock/die

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Available Options
Component Solution-------------System Replacement
High
Low
Cost
Risk
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Finding the same part ...
1980
2001
Boeing McDonnell Douglas Hughes
Helicopter Rockwell General Dynamics Lockheed Mart
in Marietta United Technologies Grumman Northrop L
TV Fairchild Kaman Bell
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Defense DarwinismImpacts

• Mergers, buy outs, die-offs result in
• Product Line Consolidation
• Redefinition of sustained products
• Division spin-offs
• Changes to manufacturing techniques

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Defense Darwinism

• Makes finding listed part DIFFICULT!
• Beware of Part Number Changes!
• Discontinuation Notices are not final
• Industry thrives on cash
• Sometimes it only takes a phone call
• Check for alternate suppliers
• Requires comparison of parametrics
• Usually requires testing

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Get off the obsolescence treadmill!
F/A-18C/D Waterfall

• Couple
• Parts Evaluation
• with
• Design Evaluation
• Lets incorporate reliable solutions
• Appropriate use of parts with design applications

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Incorporate Design Tradeoffs
Do we really need Full MIL-TEMP range??

• Incorporation of industrial grade (-40C - 85C)
• Reqd startup of A/C cooling system prior to
  power on

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ResourcesModule/Subassembly Replacement

• Many OTS subassemblies available that duplicate
  performance -- BOLT-ON REPLACEMENT!
• Excellent candidates for power supplies/EMI
  filters
• AAIPT -- acceptable solution for 10 of
  obsolescence solutions

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ResourcesMinor board level redesign, Mod of
existing board

• Alternate part part available in dif pkg/pinout
• Alt part is functionally different, but SRA
  requirements unchanged
• Board-level testing/Potential TPS changes

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ResourcesBoard-Level Redesign

• Good Option
• Multiple obsolescence problem
• Board wear-out
• Functionality changes (mission)
• Risk
• All All interfaces properly defined
• Linear over operating temperatures
• Throughput
• Probable TPS/Software changes

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ResourcesWRA-Level Redesign
Example -- CAINS
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ResourcesSystem-Level ReplacementMultiple WRA
Redesign

• Requires
• Systems-Level analysis
• Major Logistics impact
• Proper definitions
• Completely new obsolescence analysis (esp. COTS)
• RISK

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DMEA/ARINC Case History
Alternate available 2/3rds of the time
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NAVAIR Case History

• Avoidance to date -- 19.6 Million
• Savings to date -- 4.5 Million

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APG-65 Radar Example

• 5 WRAs
• 553 microcircuits
• 40 obs. components
• 4 SRAs impacted multiple times
• expensive hybrid design
• 1-11K per device

Options
A. Emulation _at_ SRA level B. DMEA Flexible
Foundry C. Procure from Raytheon Sister
Company
Which is most cost effective?
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APG-65 Options
Multiple components on several cards High cost
components Uncertain supplier Decision Mixture
of card and component emulation
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Conclusions
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Conclusions
1. Weapon service life uncertain
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Conclusions
1. Weapon service life uncertain 2. Evaluate
options based on a. Existing FY cost b. 7-year
window c. Weapon LCC
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Conclusions
1. Weapon service life uncertain 2. Evaluate
options based on
a. Existing FY cost b. 7-year window
c. Weapon LCC 3. Integrated weapon system
evaluations - cant chase chips
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Conclusions
1. Weapon service life uncertain 2. Evaluate
options based on
a. Existing FY cost b. 7-year window
c. Weapon LCC 3. Int. wpn sys. evaluations -
cant chase chips 4. Current toolsets inadequate
to assist PMs with decision process