NAVAIR Commercial Off the Shelf Technology Insertion

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NAVAIRCommercial Off the ShelfTechnology
Insertion

• Dr. Don McErlean
• AIR 3.0
• 05 November 2002

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INTRODUCTION COTS what does it mean?
History Organizations/Efforts
Experiences Limitations
Recommendations
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COTS Many things to many people Is it
Commercial Off The Shelf Cant
Often Find The Support Hardware/Software/Se
rvices Key Impact of Any Support Fleet
Readiness
If the Process does not result in Greater Fleet
Readiness than why do it?
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COTS-O-Meter

• Many COTS options available

level of militarization
NEW CONNECTORS
REPACKAGE
CONFORMAL COAT
REDESIGN
FULL MIL
OFF THE SHELF
SRA failures program cost program schedule
xxx
xxM
xxm

• DoD Applications
• Dial too far left - it wont run in your system
• Dial too far right - you cant afford it.

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History Specification Insanity -
Potato Chips - Paint on Fuel Controls
Requirements Over-Kill Out of Control
Costs Rapid Obsolescence Lt X and the
Radio Shack solution
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Organizational Efforts
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Using commercial technologies to reduce DoDs
operation and support costs
Commercial Operations Support Savings
Initiative (COSSI) Program
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(No Transcript)
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COSSI Business Model Fast Technology Insertion
Subsystem or component
Kit
Go/No-Go Decision
Stage II Sponsor and PM fund fleet-wide
installation of kits and track savings
Fielded Military System
Sustainment Concept
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COSSI Projects on the H-53
Integrated Mechanical Diagnostics / Health
Usage Monitoring System (IMD-HUMS)
FY97
Insert commercially available automated
diagnostic and decision-making system aboard the
H-60 and H-53 helicopters using open architecture
and commercial interfaces
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COSSI Projects on the AH-1Z / UH-1Y
FY99
Integrated Mechanical Diagnostics / Health
Usage Monitoring System (IMD-HUMS)
Readiness improvement of 12 (est.) Cost
avoidance per aircraft through 2010 of 1.3M
(est.) for a projected 25-year total of 1.2B
Ground station Integrated with NALCOMIS
180 AH-1Z Aircraft
100 UH-1Y Aircraft
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Why are we Doing this Anti-Corrosion Effort?

• Answer mail from Fleet
• Reduce Total Ownership Costs
• Reduce Maintenance Workload on Fleet Maintainers
• Lengthen Time Between Maintenance Intervals
• Increase Life of Airframe Structure, Propulsion
  and Avionics
• Utilize COTS Products that exceed Mil Spec for
  Aviation
• Evaluated on
• P-3C-3 years 90 Reduction of Corrosion
  Maintenance (DINOL AV-30)
• S-3B-47 Reduction of Corrosion Maintenance
  (ACF-50)
• H-60 Series-50 Reduction of Corrosion
  Maintenance (Fluid Film)

Untreated Aircraft Lap Joint
Treated Aircraft Lap Joint
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E-2C Hawkeye
Bubbled paint on top of wing along rivet heads
Paint peeling off in sheets on port aft side of
aircraft
Surface and internal corrosion on Rotodome
Corrosion Internal to Rudder,Tail Bolts
Blistered paint and hot spots on wings
Corrosion Internal to Wing Spars (during wing
fold position)
Exfoliation and corroded rivets on belly seam
Surface corrosion on launch bar
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What Coatings are being Evaluated ?
Before CPCs
After CPCs

• Super-penetrating
• Water displacing
• Lubricate Structures
• Corrosion inhibiting
• Tack-free Hard film

• Polarization Bond
• Penetrate Lap Joints
• Lubricate Structures
• Dielectric
• Displace Moisture
• Soft Film

Website http//www.oakite.com/
Website http//www.corrosionx.com
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Patuxent PartnershipSmall Business Incubatorfor
NAVAIR
Pax Partnership Small Business Incubator Recent
Success Stories
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Patuxent Partnership Success Stories
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Conformal Patch Antenna Arrays

• Use of Conformal Patch Antenna Arrays
• High Side-lobe Suppression
• Phased Array (Electronic Steerable Antenna)
• Capable of Full Wave Antenna dB Gain (Omni or
  Beam)
• Impedance Matching Circuit
• UHF
• VHF
• HF
• X Band Fire Control Radar's
• S Band 2-D/3-D Search Radar's
• BI-Static Radar Applications
• GPS
• Millimeter Wave

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Limitations (E-2 Example)
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• COTS ACIS Workstation Hardware
• ACIS was closer to off-the-shelf
• Conformal coating on boards, but not repackaged
• Several problems with FFFI but vendor is
  amenable and making good on the product
• Oops! Making good takes time ... time and
  resources from your program.
• Each year, parts change this affects new
  purchases, spares, and repairs.
• Oops! Class II changes to the vendor become
  Class I changes to our platform.
• Lesson Learned Establish an Industry/Gov team
  to maintain proper configuration.
• Good news! Unit cost dropped over 60 by being
  part of a larger COTS commonality procurement.

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E-2C Software Challenge
LINK 4/11/16 changes
fleet
outside factors
MIST Pax River
CEC 680X0 based
ACIS HP Anole based
MC DEC Alpha based
OS Motorola
UNIX OS HP
UNIX OS DEC
diagnostics LM
diagnostics Motorola
diagnostics NGC
C by APL
C by APL
MC Ada OFP by NGC 400K SLOC
E-2C display by PMA-231 275K SLOC
CEC Ada OFP by NGC 300K SLOC
Changes in any block can affect any other
block
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• COTS Software Challenge
• Database started as Oracle
• it was way to slow.
• Rationale 1500 banks cant all be wrong.
• Oops! Program lost about 6 months going to
  another database.
• Lesson Learned Perspective - Fast for industry
  is slow to DoD .. do your systems analysis first

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• COTS Software Challenge
• Mission Computer Operating System (OS) started as
  Multi-Level Secure Plus (from DEC)
• 3 years later the vendor decided there was no
  market, we were informed it would not be
  supported.
• Oops! Program lost time inserting another OS.
• ACIS OS is HP UNIX and the attendant yearly
  updates.
• Oops! Yearly software releases for new
  production
• Lesson Learned Plan on change

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E-2C Mission System COTS If each doesnt work,
our AO 0
Advanced Control Indicator Sets (workstation)
COTS
COTS
Data
Loader/Recorder
software
COTS
XServer
COTS
HP UNIX
COTS
Barco driver
COTS
APL OFP
software
LM diagnostics
COTS
software
COTS
Mission Computer
DEC MLS OS
COTS
HP UNIX
COTS
tools (Ada)
MIST Mission Information Software Transfer
Station (squadron level)
TAMPS
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• Issues a thought about testing
• COTS means Technology Insertion (TI)
• leads to new products with greater
  performance at a regular cycle
• (perhaps with each new purchase ?)
• How are performance increases going to be tested
  ?
• ?? More OPEVALs ? maybe
• ?? Provide more rigorous testing not through
  classical means, but by improving use of
  simulation.
• Plan on things leaving the inventory faster.

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To Be Successful Validation must be done in Fleet
environment It must operate It must be
maintainable It must have sustainable
support Obsolescence must be considered
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• and color of money
• The color of money situation is
• RD funding from the program office has a
  bell-shaped curve these funds end after
  development
• OS funding (logistics) pick up after
  development
• The key phrase is after development.
• The problem with COTS TI is there is no after
  development.
• We are having difficulty determining the
  correct color of money.
• Proposal
• Establish comptroller rules to ensure
  life-cycle support for COTS equipment.

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• Summary ... COTS means
• Be prepared for change .. have your team in
  place to handle continuous challenges.
• We have to work on the color-of-money problem.
• We have to determine a position regarding
  testing when TI brings product change.
• Work with industry to strive for more
  efficiencies.
• The COTS big-win is the ratio of performance to
  cost compared to traditional developments.

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IF IT DOES NOT BRING SUSTAINABLE, AVAILABLE,
RELIABLE CAPABILITY TO THE FLEET DONT DO
IT!