Economics of Human Systems Integration:
The Pratt & Whitney F119 Engine
Dr. Ricardo Valerdi
2ndLt. Kevin Liu, USMC
Dr. Donna Rhodes
Background
Industrial Revolution - WWII
Human Engineering Guide to
Equipment Design
US Human Factors Society
1980s
UK Ergonomics Research Society
Government Agency focus on
safety and human factors
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HSI in the Air Force
Environment—the conditions in and around the system and
the concepts of operation that affect the human’s ability to
function as a part of the system as well as the requirements
necessary to protect the system from the environment.
Manpower—the number and mix of
personnel (military, civilian, and
contractor) authorized and available to
train, operate, maintain, and support each
system.
Survivability—the ability of a system, including
its operators, maintainers and sustainers to
withstand the risk of damage, injury, loss
of mission capability or destruction.
Habitability—factors of living and working
conditions that are necessary to sustain the
morale, safety, health, and comfort of the user
population that contribute directly to personnel
effectiveness and mission accomplishment, and
often preclude recruitment and retention
problems.
Occupational Health—the consideration of design
features that minimize risk of injury, acute and/or
chronic illness, or disability, and/or reduce job
performance of personnel who operate, maintain, or
support the system.
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Personnel—the human aptitudes, skills, and
knowledge, experience levels, and abilities
required to operate, maintain, and support a
system at the time it is fielded.
Training—the instruction and resources
required providing personnel with
requisite knowledge, skills, and abilities
to properly operate, maintain, and
support a system.
Human Factors Engineering—the comprehensive
integration of human capabilities and limitations into
systems design, to optimize human interfaces to
facilitate human performance in training operation,
maintenance, support and sustainment of a system.
Safety—hazard, safety and risk analysis in system design and
development to ensure that all systems, subsystems, and their
interfaces operate effectively, without sustaining failures or
jeopardizing the safety and health of operators, maintainers and
the system mission.
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Economics of HSI
DoDI 5000.02, Operation of the Defense Acquisition System
(Begins)
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Research Questions
• How did Pratt & Whitney predict how much
HSI effort would be needed?
• How much did HSI effort eventually cost?
• How did HSI fit into the larger systems
engineering picture?
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The F-22 Raptor
Air Superiority Fighter
Replaces F-15
Air dominance, multi-role fighter
Dominance through stealth,
speed, agility, versatility,
supportability
First Look – First Shot – First Kill
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The Pratt & Whitney F119 Engine
Best practice of HSI
Reliability & Maintainability emphasis from 1984 ->
-Air Force leadership
New requirements
introduced during
Engineering and
Manufacturing
Development (EMD)
P&W F119 beat GE
F120 because it
demonstrated “least
technical risk and
lowest cost”
Yankel, J. & Deskin, W. (2002). “Development of the F-22 Propulsion System.”
Engine Design for the Mechanic
Integrated Product Development (IPD)
Integrated master plan (IMP), Integrated Master Schedule (IMS), Integrated Product
Teams (IPTs), Integrated Program Management Team (IPMT) Component IPTs
(CPTs).
Supportability Awareness
“Blue Two” visit program.
Internal presentations reiterated lessons learned.
Supportability Reviews and Trade Studies
Monthly reviews evaluated adherence to IMP and IMS.
Over 200 studies weighed HSI features against cost, weight, and performance.
Early Support Tool Involvement
Tools annotated to design drawings
Full-Scale Engine Mockup
Full-scale engine mockups used to test reality of one-deep LRU - allowed engineers
to simulate servicing parts.
Held engineers accountable.
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© 2008 Massachusetts Institute of Technology
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HSI Early in F119 Development
AF Acquisition Community-led
requirements definition studies
40% fewer parts than previous
engines
Leadership and IPD
…advances were intended to reduce operational level and
intermediate level maintenance items by 75% and depot
level tools by 60%, with a 40% reduction in average tool
weight,” (Aronstein, et al. 1998).
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F119 Successes Span
Domains of HSI
HSI Domain
Manpower
Personnel
Training
Work Done
- All maintenance tasks designed
to accommodate women
maintainers
- Documentation
Human Factors -6 Tools total
Engineering - 1 Tool/ LRU, One-Deep LRU's
- Tools redesigned for easier
(HFE)
Cost
Benefit
-Fewer Maintainers
-Men and Women could work on engines
- Reduced man-hours spent on maintenance
-Improved understanding of procedures
- Effort spent preparing
documentation
- Weight
handling
Environment
Safety
- Captured Fasteners
- Self-contained engine
- Weight
Occupational - CBR Suits
Health
Habitability
- Mock-Ups
- "Blue Two" Visits
Survivability
-Designed to contain fan blades
- Single-engine mentality
-Fewer reported mishaps
-Reduced exposure to harmful elements
-Funding for trips
- $2M/ Mock-Up
-Zero Scheduled Maintenance
- Reduced engine failure rate
- 75% reduced O&I time
Development of Cost Drivers
The 10 Principles of Effective HSI (from
the Handbook on HSI)
1. Top-level leadership
2. Focus on human-centered design (HCD)
3. Source selection policy
4. Organizational integration of all HSI
domains
Prioritized List of Critical Elements for
Successful HSI (from The Art of Successfully
Applying Human Systems Integration)
1. Management and Organizational
Commitment
2. User/stakeholder involvement
3. Education and awareness of all
5. Documentation integration into
procurement process
4. HSI process ownership
6. Quantification of human
parameters
6. Funding support
5. Holistic, enabled view
7. HSI technology
7. Documented and technically sound
processes
8. Test and evaluation=assessments
8. Qualified personnel
9. Highly qualified practitioners
9. Open collaborative environment
10. Education and training program
10. Practical applications based on sound human
factors research
(Booher, 2003)
(Landsburg et. al., 2008)
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Observations
•How did Pratt &
Whitney predict how
much HSI effort
would be needed?
• USAF Requirements-driven
• Competition, Business
need
•How much did HSI
effort eventually
cost?
• Estimation by analogy
•“HSI Slice” unclear
•How did HSI fit into
the larger systems
engineering picture?
• IPD, CICR, CCB, IPT, CIPT, etc.
• Emphasis in requirements,
pre-milestone A/B
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Development of Cost Drivers
Existing COSYSMO Cost Drivers:
– Requirements Understanding
– Architecture Understanding
– Level of Service
Requirements
– Migration Complexity
– Technology Risk
– Documentation
– # and diversity of
installations/platforms
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– # of recursive levels in the
design
– Stakeholder team cohesion
– Personnel/team capability
– Personnel experience/continuity
– Process capability
– Multisite coordination
– Tool support
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COSYSMO
200 easy,
200 nominal,
50 difficult
Requirements
2 easy, 3 difficult
Interfaces
5 difficult
Algorithms
Size
Drivers
Effort
Multipliers
COSYSMO
195
Person Months
of HSI effort
High Requirements Understanding
High Technology Risk
High Process Capability
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Acknowledgments
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