Configuration Management Challenges
with the V-22
Osprey
CMBG 2011
18th Annual Configuration Management
Benchmarking Group (CMBG) Conference
Sheraton Society Hill
Bruce Oestreich
Director
Systems Engineering
Boeing Military Aircraft
June 22nd 2011
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AGENDA
CMBG 2011
Incredibly Brief V-22 Program Overview
V-22 CM Challenges
Engineering / Production / CM / Support Tools
Production Flow of Fuselage through Final Delivery
Waivers / Deviations
Complexity of System Specification
New traceability on both sides
Early Incorporation vs Retrofit
Recommendations for the Nuclear Industry
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What We Do
Work Split
Philadelphia, PA
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



Fuselage
Landing Gear
Avionics
Electrical and Hydraulic
Performance
Flying Qualities
Empennage
Ramp
USMC
360 MV-22
Combat Assault &
Amphibious Assault
Sustained Land Operations
Program of Record
Fort Worth, TX
 Composites
 Rotor
 Dynamics
Amarillo, TX
 Wing / Nacelle
 Over-wing Fairing
 Final Assembly
 Flight Test/Delivery
USN
USSOCOM
50 CV-22
48 MV-22
Long Range Special
Operations (SpecOps)
Contingency Operations
Fleet Logistics Support
Personnel Recovery
Special Warfare Support
Making an Impact
CMBG 2011
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Current Program Status
CMBG 2011
• 10 USMC and 3 AFSOC Squadrons operational

156 aircraft delivered (137 MV-22 /19 CV-22)
• Exceeded 100,000 flight hours on the fleet; over 50% in last 2 years
• Readiness Improvements In Progress
• 5-year, $4.6B Multi-Year Procurement (MYP) contract - Mar 2008

167 aircraft (141 MV-22, 26 CV-22) with options
• Second MYP in work for 122 Aircraft, $4B with options
• 5-year Performance Based Logistics (PBL) Contract
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Phase I (Integrated Logistics Support Management) signed Jan 09

Phase 1.5 – (Reliability & Maintainability improvements) signed Jun 09

Phase II (Supply Chain Management) estimated contract in 3Q 2011
• Growing domestic and international interest
Ospreys are Fielded and Maturing
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Long Term Delivery Profile
Fuselage Deliveries
CMBG 2011
Actual | Projected MY I | Projected MY II
Annual production rate declines after Multi-Year 1
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V-22
Osprey
CMBG 2011
Configuration Management
Challenges
Configuration Management is the process of identifying and defining the
items in the system, controlling the change of these items throughout
their lifecycle, recording and reporting the status of items and change
requests, and verifying the completeness and correctness of items.
-- IEEE-Std-729 (1983)
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Different Considerations for
Configuration
Management
CMBG
2011
• We all understand the importance of tracking the
delivered item; but what about:
–
–
–
–
–
Hardware / Software Tools used to develop and deliver it?
People who interact with the entire process?
Different environments through which it traveled?
Data used to track development?
Services provided along the way?
• In most instances, keeping configuration control
of these elements is just as critical as knowing
about the end product
• What does your Customer expect?
– What will your Customer accept?
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V-22 Configuration – Specific Challenges
CMBG 2011
• Engineering / Production / CM / Support
Tools
• Production Flow of Fuselage through
Final Delivery
• Waivers / Deviations
– Complexity of System Specification
– New traceability on both sides
• Early Incorporation vs Retrofit
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V-22 Configuration History
CMBG 2011
• Some basic airframe parts derived from Full Scale
Development (FSD) program – 1985
– Mylar Drawings
– Some 2-D CAD/CAM drawings
• Some aircraft design components carried over
from the Engineering & Manufacturing
Development (EMD) program – 1992
– Introduction of CATIA 3-D
• Currently in Lot 14 of Production
– Goal of limiting configuration changes to Lot
Effectivity not practical / achieved
– Customer desire to incorporate new changes as
soon as possible
• Incorporation in earlier aircraft minimizes retrofit activity
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Engineering / Production / CM / Support Tools
•
It would be much easier ifCMBG
we only2011
had to worry about the Aircraft itself
–
Instead – there are multiple products to track and maintain
•
•
•
•
•
Aircraft Hardware and Software
Technical Publications and all Technical Data
Trainers – Maintenance, Part Task, Aircrew, etc…
Simulators – Maintenance and Flight
Now consider conflicting / incompatible tools that hinder configuration
management
–
–
–
Engineering data in one system
Production data in another system
CM in database – tries to interface with others
•
Boeing system / Bell system / Government system all different (Corporate
commonality)
• Configuration Management of the tools is just as critical
as CM of the products!
• What did we do to overcome?
– Communications! Asked each other for HELP!
–
Configuration Audits to strike common baseline (Goodness!)
•
–
Resulted in Closed Loop Corrective Action process
Improved CM processes (Continual)
– Customer Involvement
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Engineering / Production / CM / Support Tools
CMBG 2011
-500
Software
Installation
Drawing
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Keeping Track of Fuselage Configuration through
FinalCMBG
Delivery
2011
•
Once drawings and planning released – we just build the
fuselage – RIGHT??
•
There are as many as 14 opportunities where configuration
changes can be incorporated that must be managed
– Engineering Effectivities
– Manufacturing Planning paperwork
•
Unique Issues with the ‘Boeing’ fuselage
– Boeing paperwork ‘closed out’ upon fuselage completion in PHL
– When changes occur in Amarillo – which paperwork / CM system do
we manage / track changes?
•
Another challenge is managing CM after delivery of the
aircraft to the Customer (“post-DD250”)
– Warfighter sometimes changes configuration out of necessity and our
CM baseline is at risk
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Opportunities for Insertion of Configuration
Changes throughoutCMBG
the 2011
Fuselage Build Cycle
Subsystem
Primary
System
Primary
1
C
M
2
Prep to
Ship
Fuselage
Primary
3
C
M
4
C
M
7
C
M
10
C
M
Amarillo
Wing Mate
Fuselage
Storage
6
5
8
C
M
9
Fuselage Completed
Paperwork Closed Out
Final
Assembly
Post DD250
Changes
Flight
Operations
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C
M
12
13
C
M
Customer
Acceptance
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14
Waivers / Deviations
CMBG 2011
• V-22 Weapon System Specification –
– Original Release – Oct 1985
– Over 5,000 pages of detailed requirements
• Current Multi-Year Procurement (MYP)
Contract – Fixed Price Incentive Fee (FPIF)
– Spec interpretation conflicts are common
– Deviations utilized to resolve conflicts
• Still an issue after 25 years
• How did we resolve this?
– Work in Progress
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Recent V-22 Deviation History (Example)
CMBG 2011
Normalized Data
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Early Incorporation vs Retrofit
•
CMBG 2011
Goal for maintaining configuration management is to
minimize the amount of changes for improved accuracy
tracking
•
Preferred Approach
– Limit Configuration Changes to known / planned incorporation points
•
New Production Lot / New Contract / etc…
– Allows for stable configuration to mature and learning curve
objectives to be met
•
Customer Challenges (Conflicting Goals)
– Acknowledge preferred approach
– Also committed to provide as much capability as soon as possible
– Change Incorporation: Production Line disruption vs Retrofit
•
•
•
Early on in program – Retrofit Funding not identified / targeted
Customer typically accepted risk of learning curve / production disruption
to ensure Warfighter received maximum capability at the earliest possible
point
Think ahead regarding Obsolescence Issues
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Recommendations for the Nuclear
CMBG 2011
Industry
Refine Your Pro-Active Parts Obsolescence
Management Program
– V-22: DoD 2007 Industry Award
Plan for Configuration Changes
– Minimize iterative changes
– Don’t change the same part
3 different times if you can all at once
Develop Strategic Plan for each site
– Communicate with Customer!
– Then Communicate some more!
– Anticipate changes and plan accordingly
Ensure alignment on definitions
– Determine ‘business case’ to ensure configuration changes done at
the right time for the right reasons
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Summary
CMBG 2011
• Configuration Management challenges exist
in every Industry in every aspect of daily
operations
• Managing expectations with Customers will
go a long way in reducing CM challenges
• Be Pro-Active! Anticipate and plan for
known / likely changes
• Utilize HELP NEEDED as a positive! You
don’t have to do it alone!
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CMBG 2011
QUESTIONS?
Bruce Oestreich
Director
Systems Engineering & Integration
Boeing Military Aircraft
bruce.d.oestreich@boeing.com
Office: 610 591 3410
Cell: 610 348 3286
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