SYSTEMS ENGINEERING

APPROACH

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Systems Engineering Concept

 SYSTEMS ENGINEERING is an interdisciplinary approach

encompassing the entire technical effort to evolve and verify an
integrated and life-cycle balanced set of system product and
process solutions that satisfy customer needs.
MIL-STD-499B, 1993

 Translation of customer needs into system parameters.

 Optimize total system design (design integration)

 Meet performance, cost and schedule objectives

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 Systems Engineering Concept

 SYSTEMS ENGINEERING is the application of scientific and engineering

efforts to

a. transform an operational need into a description of system

performance parameters and a system configuration through
through the
use of an Iterative
iterative process of definition, synthesis, analysis,
design, test, and evaluation;

b. integrate related technical parameters, and ensure compatibility

of all physical, functional, and program interfaces in a manner
that optimizes the total system definition and design;

c. integrate reliability, maintainability, safety, survivability, human,

and other such factors into the total engineering effort to meet
cost, schedule, and technical performance objectives.

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Systems Engineering Concept

 SYSTEMS ENGINEERING is an interdisciplinary field of engineering, that

focuses on the development and organization of complex artificial
systems.

 Systems engineering integrates other disciplines and specialty groups

into a team effort, forming a structured development process that
proceeds from concept to production to operation and disposal.

 Systems engineering considers both the business and the technical

needs of all customers, with the goal of providing a quality product
that meets the user needs

 Systems engineering techniques are used in complex projects.

 Systems engineering uses a host of tools that include modeling &

simulation, requirements analysis, and scheduling to manage
complexity.
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 Systems Engineering Concept

IMPORTANCE OF SYSTEMS ENGINEERING IN AERONAUTICAL INDUSTRY

 Cost Reduction
• Aircraft (Design and Manufacturing)
• Operation (Product performance)
• Support
• Worldwide competition, mergers
• Cost price < sales price

 Improved Performance/Quality
• Suppliers -> buyers market
• Technology push -> market pull
• Market/customers satisfaction
• Client specifications -> flexibility (spec’s)
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Systems Engineering Concept

IMPORTANCE OF SYSTEMS ENGINEERING IN AERONAUTICAL INDUSTRY

 Reduction of development/lead time

• Competition advantage (manufacturer/airline)
• Flexibility in production rate
• Delivery time reduction

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 Systems Engineering Concept

OPERATING ENVIRONMENT

OPERATORS

TECHNOLOGY CUSTOMER/MARKET
DRIVEN DRIVEN
DEVELOPMENT TECHNICAL SYSTEMS DEVELOPMENT

MANUFACTURERS

TECHNOLOGY

Source: R.J. van Baaren, September 1996

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Systems Engineering Concept

Airline Operating Environment
Global Recession Deregulation High Growth Industry Environmental Awareness

Airlines
Poor financial performance Global competition

Reduce workforce Increasingly demanding

Reduce orders Cooperation Improve productivity customer requirements

Aircraft Good Quick Cheap

Satisfies Short time-to-market Low operating cost
customers need Short lead time Low acquisition cost
High quality On time Affordable

Manufacturers
Reduce budgets Changing design Cooperation
and resources or (PRP) process
Source: R.J. van Baaren, September 1996
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 Development of Systems Engineering
1950s Polaris  Project management
 Network scheduling

1960s Air Force  Aircraft servicability

 Reliability / maintainability

1970s Forces  Program / Baseline management

 Cost-effectiveness

1980s Forces  DFMA / DTC

 ILS / LSA / LCC

1990s Government/  SE / Concurrent Engineering

Industry  CALS
 Make or Buy / Contracting out

2000s Industry  Distributed design-built teams

 Distributed manufacturing
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System Definition
SYSTEM

Research & Hardware Manufacturing Operation Support Process

Development Software Assembly Support • Maintenance process
Training • Documentation
• Spares, facilities
• Training

 Whole life considerations  Life cycle phases

 Life cycle cost

 Integration of disciplines  Engineering

 Support
 Marketing
 Manufacturing

 System  Hardware
 Manufacturing
 Support
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 Systems Engineering Management
Controls the design
process and provides
 Concept Level
baselines that Development  System Level
coordinate design Phasing
 Subsystem/Component
efforts
Level
Life Cycle
Baseline Planning
Provides a Systems Involves
structure for Engineering customers in the
solving design Management design process
problems and Systems and ensures that
Life Cycle the system
tracking Engineering
Integrated Integration developed is
requirements Process
flow through the Teaming viable
design effort throughout its
life

Three Major Activities of Systems Engineering Management

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Systems Engineering Process

PROCESS INPUT

System
Requirements Analysis and
Analysis Control
Requirements (Balance)
Loop
Functional
Analysis and
Allocation
Design
Loop
Verification Design
Synthesis

PROCESS OUTPUT
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 Systems Engineering Process

Customer
Needs

 Identify customers
 Understand customer needs
 Establish the need for change
State the  Discover system requirements
Problem  Verify and validate requirements
 Define system functions.

 Define quantitative measures

Investigate  Performance and cost criteria show how well the
Alternatives system satisfies its requirements
 Technical performance measures are used to track
the progress of design and manufacturing
 Measures are often related to the process, not the
product.

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Systems Engineering Process

Prescribe tests

Conduct and document reviews

Total system test

During the operation and

maintenance phase of the system
 The most important
life cycle, system’s performance
task of Systems
Assess must be measured:
Engineering
Performance  Initially, to verify that the
 Use feedback to
system is in compliance with its
control systems and
requirements
improve performance.
 Later, to detect deterioration
 Observe outputs and
Product and initiate maintenance
using this information
to modify the system and
inputs, the product or Process
the process.
 Re-evaluation should be a continual process with many parallel loops.
 Everyone should continually re-evaluate the system looking for ways to improve quality.
 Tools used include basic systems engineering, and the quality engineering techniques.
 Near the end of the project, engineers should write a Lessons Learned document.
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 Systems Engineering Process

 Design the system

 Create sequence diagrams
 Define system architecture
Model the  Functional analysis
System  Sensitivity analysis
 Assess and manage risks
 Reliability analysis

Integrate
System  Design and manage interfaces
Components

 Configuration management
Launch the  Project management
System
 Documentation
 Lead teams

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Sequential vs Concurrent Engineering

 Often the product design process and the design of its manufacturing
system must be carried out simultaneously; hence the need for the
study of the concurrent engineering to effectively perform this
integration.
 This requires a Design-Build Team.

 Concurrent Engineering is a systematic approach to the integrated,

concurrent design of products and their related processes, including
manufacture and support.

 This approach is intended to cause the developers, from the outset,

to consider all elements of the product cycle from concept through
disposal, including quality, cost, schedule and user requirements.

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 Sequential vs Concurrent Engineering

Product Development without Concurrent Engineering

Reassess market impact Product

Cost
Model

Market Product Product Product Process Volume

Needs Specification Design Testing Development Production

Respecify Redesign

Product
Testing

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Sequential vs Concurrent Engineering

Product Development with Concurrent Engineering

Process
Technology

Manufacturing Production
Process
Cost Process
Specification
Feedback Development

Market Research
Competitive Volume
Assessment Marketing Launch Production
Concept Design

Product
Product Product
Design &
Specification Testing
Analysis
Design
Enabling
Technology

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 Sequential vs Concurrent Engineering
Decision
BOR Expenditure outcomes
PRR
100 Major review

Leverage Expenditure
Opportunity

(%) (E)
Business

Expenditure (E)
Study

Feasebility
Study

Definition
Project

CPR
Full Scale
Development

12-15 Leverage on total

expenditure
outcome (L)
Time (mo) Project complete
BOR = Business Opportunity Review PRR = Project Requirement Review CPR = Critical Project Review
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Concurrent Engineering At Boeing

 With increased competition, a focus on customers, and reduced

cycle times, skills from all functional groups are needed at all stages
of a product’s development.

 This requires a strategy based on the concept of concurrent

engineering.

 Concurrent engineering is the effective simultaneous development

of different disciplinary subsystems required for a product launch.

 It focuses on merging technical and business specialties to produce

quality products on short time scales.

 At the heart of concurrent engineering is the idea of

multifunctional teams, also known as integrated product teams.

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 Concurrent Engineering Process At Boeing
Systems

Analysis

Initial Loads Design Analysis

Complete
Conceptual
Manufacturing plan Structures Final datasets Freeze Period Releases

Transfer Fault Reduction

Feedback

Manufacturing Engineering Detail planning Releases

Producibility Assessment

Tool
Tool Engineering Final Tool Designs Releases
Concepts

Milestones
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