Part 2 : System Design & Development.

Ch.6 Preliminary & Detail Design.

Edited by Dr. Seung Hyun Lee (Ph.D., CPL)
IEMS Research Center, E-mail : lkangsan@iems.co.kr

 Preliminary Design.
[Blanchard, pp150 - 180]

Feedback

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 Preliminary Design.
[Blanchard, pp150 - 180]

Functional Analysis.
Process of Functional Analysis.
A "function" refers to a specific or discrete action that is necessary to

achieve a given objective.

The functional analysis is an iterative process of breaking requirements

down from the system level, to the system, and as far down the
hierarchical structure as necessary to identify input design criteria and/or
constraints for the various elements of the system.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Functional Analysis : Example.

Functional Block Diagram : Operational Function.

Maintenance Function.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Functional Analysis.
Roles of Functional Analysis.
That all facets of system design and development, operation, support, and

retirement are covered ; that is, all significant activities within system life
cycle.
That all elements of the system are fully recognized and defined ; that is,

prime equipment, spare/repair parts, test and support equipment, facilities,

personnel, data, and software.
That a means is provide for relating system packaging concepts and

support requirements to specific system functions ; that is, satisfying the

requirements of good "functional" design.
That the proper sequences of activity and design relationships are

established, and with critical design interfaces.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Functional Analysis.
Roles of Functional Analysis.
Electrical and mechanical design for functional packaging, condition
monitoring and diagnostic provisions.
Reliability models and block diagram.
Failure mode, effect, and criticality analysis (FMECA).
Fault-tree analysis (FTA).
Reliability-centered maintenance (RCM) analysis.
System safety/hazard analysis.
Maintainability analysis.
Level-of-repair analysis.
Maintenance task analysis (MTA).
Operator task analysis (OTA).
Operational sequence diagrams (OSDs).
Supportability analysis.
Operating and maintenance procedures.
Producibility and disposability analysis.
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 Preliminary Design.
[Blanchard, pp150 - 180]

Allocation of Requirement.
Allocation.
Given a top-level definition of the system through the functional analysis,

the next step is to break the system down into components by partitioning.
This involves a breakdown of the system into subsystems and lower-level
elements. The partitioning of the system into elements is evolutionary in
nature.
Given the identification of system elements, the next step is to allocate or

apportion the requirements specified for the system down to the level
desired to provide a meaningful input to design.
This involves a top-down distribution of the quantitative and qualitative

criteria.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Allocation of Requirement.
Reliability Allocation.
After an acceptable reliability factor or failure rate has been established for

the system, it must be allocated among the various subsystems, units,

assemblies, and so on.
The allocation commences with the generation of a reliability block diagram.

Reliability Allocation Techniques.

Equal Apportionment Techniques.
ARINC Apportionment Techniques.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Reliability Allocation.
Equal Apportionment Technique
This technique is a straightforward method that assigns equal reliability

requirements for

all subsystems based on the system requirements. While

being easy to compute, it lacks the sophistication to discriminate between

actual subsystem reliabilities.

Rsys = (R 1)(R 2)(Rn)

where R1, R2, , Rn are individual subsystems.

1
n

R i =(R sys ) , i

1, 2, , n

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 Preliminary Design.
[Blanchard, pp150 - 180]

Reliability Allocation.
ARINC Apportionment Technique.
The failure rate for the system is first determined and then previous history

or other estimation methods are used to provide a weighing( wi) for each
subsystem to determine what the individual subsystem failure rate must be
to achieve the system reliability requirement. The methods for calculating
the weighting factors.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Reliability Allocation.
ARINC Apportionment Technique.
Step 1. Using available information or other estimation techniques,
estimate the subsystem failure rate i for each subsystem.
Step 2. Calculating the weighing ( wi) for each subsystem as a proportion
of the subsystem failure rate to the entire system failure rate.
w i=

i = 1, 2, 3, , n

w i= 1

i=1

i=1

Step 3. The subsystem failure rate requirement is then calculated.

i= w i

system

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 Preliminary Design.
[Blanchard, pp150 - 180]

Maintainability Allocation.
Maintainability Allocation Procedures.
Example.
1. An inherent availability requirement of 0.9989.
2. MTBF = 450.
3. Mct =

MTBF(1-A i )
= 0.5
Ai

Thus, the system's

Mct requirement is 0.5 hour, and this requirement must be

allocated to Units A to C, and the assembles within each unit.

Contribution of
Item Quantity Failure Rate
Total Failures
A
B
C

1
1
1

0.246
1.866
0.110

0.246
1.866
0.110
Total = 2.222

Mct for system XYZ =

% Contribution
11%
84%
5%
100%

Estimated

ct

0.9
0.4
1.0

Contribution of
Total Corrective
Maintenance Time.
0.221
0.746
0.110
Total = 1.077

1.077 = 0.485 hours (requirement : 0.5 hr)

2.222
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 Preliminary Design.
[Blanchard, pp150 - 180]

Allocation of Logistics Factors.

Logistics Factors Allocation Procedures.
These factors deal with supply demand, test and support equipment,
personnel and maintenance organization, facilities and transportation.
Example : System XYZ.
1. Test equipment utilization in the intermediate maintenance shop shall be at
least 80%, and test equipment reliability shall be at least 90%.
2. Self-test thoroughness for the system shall be 95% or better.
3. Personnel skill levels at the organizational level shall be designed for a
minimum of 75% utilization.
4. The maintenance facility at the intermediate level shall be designed for a
minimum 75% utilization.
5. The transportation time between the location where organizational
maintenance is accomplished and the intermediate maintenance shop shall
not exceed 4 hours.
6. The turnaround time in the intermediate maintenance shop shall be 2 days,
and 10 days in the depot maintenance facility.
7. The probability of spares availability at the organizational level of
maintenance shall be at least 95%.
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 Preliminary Design.
[Blanchard, pp150 - 180]

Allocation of Economic Factors.

Economic Factors Allocation Procedures.
Using an approach similar to that described in previous sections, cost

factors may be allocated as appropriate to system needs. If the ultimate

product is to be cost-effective, it may be desirable to assign cost targets for
various system elements.
For instance, an objective might be to design System XYZ such that the

unit system cost is no more than $500,000, based on a production quantity

of 300 and an operational life of 10 years. Unit cost constitutes total
life-cycle cost divided by the quantity of systems. This cost factor, specified
at the top level, can be apportioned to lower equipment indenture levels as
cost targets for design. Cost targets combined with reliability requirements
may create a boundary situation for design. In other words, one can design
to a cost.
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 Preliminary Design.
[Blanchard, pp150 - 180]

Synthesis, Analysis and Design Optimization.

Synthesis.
Synthesis refers to the combining and structuring of components in such a

way as to represent a feasible system configuration.

Initially, synthesis is employed to develop preliminary concepts and to

establish basic relationships among the various component of the system.

Later, when sufficient functional definition and decomposition have occurred,
synthesis is used to further define the "hows," in response to the "what"
requirements.
Synthesis involve the selection of a configuration that could be

representative of the form that the system will ultimately take, although a
final configuration is certainly not to be assumed at this point.

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 Preliminary Design.
[Blanchard, pp150 - 180]

Synthesis, Analysis and Design Optimization.

Analysis & Design Optimization.
The synthesis process usually leads the definition of several possible

alternative

design

approaches,

which

will

be

the

subject

of

further

analysis, evaluation, refinement, and optimization.

As these alternatives are initially structured, it is essential that the

appropriate technical performance parameters to be properly aligned to

applicable components of the system.
For instance, technical performance parameters may include factors such as

weight, size, speed, capacity, accuracy, volume, range, processing time

along with reliability and maintainability. These parameters, or measures,
must be prioritized and aligned to the appropriate elements of the system
(e.g., an equipment, unit or assembly, item of software).
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 Preliminary Design.
[Blanchard, pp150 - 180]

Synthesis, Analysis and Design Optimization.

Process.
1. Definition of analysis goals.
2. Selection and weighting of evaluation
parameters.
3. Identification of data analysis.
4. Identification of evaluation techniques.
5. Selection or the development of a model.
6. Generation data and model evaluation.
7. Evaluation of design alternatives.
8. Accomplishment of a sensitivity analysis.
9. Identification of risk and uncertainty.
10. Recommendation of preferred approach.

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 Detail Design & Development.

[Blanchard, pp150 - 180]

Detail Design Process.

Detail Design & Development Process.
The detailed design and development phase begins with the concept and

configuration derived through preliminary system design: that is, a system

configuration with performance, effectiveness, logistic support, cost and other
requirements.
An overall system design configuration has been established, and now it is

necessary to convert that configuration to the definition and subsequent

realization of hardware, software, data, and specific items of support.

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 Detail Design & Development.

[Blanchard, pp150 - 180]

Detail Design Process.

Detail Design & Development Process.
1. Definition of system elements.
Subsystems, units, assemblies, lower-level component parts, software, data, and
the elements of logistics support.

2. Preparation of design data.

Specification, drawing, databases and electronics data files, trade-off study
reports, analysis results, predictions, and so on, describing all facets of the
system.

3. Development of physical models of the system or major system component.

Engineering laboratory models, service test models. mock-ups, and prototype
models for the purpose of test and evaluation.

4. Conductance of system integration and test.

The verification of system characteristics and that the requirements have been
met. Deficiencies are noted and corrected through redesign, system modification,
and retest as necessary.
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 Design Review.
[Blanchard, pp150 - 180]

Scheduling Design Review.

Conceptual design review.
The conceptual design review may be scheduled during the early part of a

program when operational requirements and the maintenance concepts have

been defined.
Feasibility studies justifying preliminary design concepts should be reviewed.
Logistics support requirements at this point are generally included in the

specification of supportability constraints and goals and in the maintenance

concept definition, generally contained in the system specification.

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 Design Review.
[Blanchard, pp150 - 180]

Scheduling Design Review.

System Design Review.
System design review are generally scheduled during the preliminary system

design phase when preliminary system layouts and specifications have been
prepared.
These review are oriented to the overall system configuration in lieu of

individual equipment items.

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 Design Review.
[Blanchard, pp150 - 180]

Scheduling Design Review.

Equipment/software design review.
Equipment/software design review are scheduled during the detailed design

and development phase when layouts, preliminary mechanical electrical

drawings,

functional

and

logical

diagrams,

design

data

bases,

and

component part lists are available.

Critical Design review.

The critical design review is scheduled after detailed design has been

completed but prior to the release of firm design data to production. Such
a review is conducted to verify the adequacy and feasibility of the design.
Design is essentially frozen at this point, and manufacturing methods,

schedules, and costs are reevaluated for final approval.

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 Test & Evaluation.

[Blanchard, pp150 - 180]

Test & Evaluation Process.

Stages of System Testing & Evaluation.

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 Test & Evaluation.

[Blanchard, pp150 - 180]

Test & Evaluation Process.

Stages of System Testing & Evaluation.
Analytical
It pertains to certain design evaluation that can be conducted early in the
system life cycle using computerized techniques to introduce CAD, CAM,
CALS, simulation, rapid prototyping and related approaches.

Type testing.
It refers primarily to the evaluation of system components in the laboratory using
engineering

breadboards,

bench

test

models,

service

test

models,

rapid

prototyping, and the like.

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 Test & Evaluation.

[Blanchard, pp150 - 180]

Test & Evaluation Process.

Stages of System Testing & Evaluation.
Type testing.
1. Environmental qualification : temperature cycling, shock and vibration,
humidity, sand and dust, salt spray, acoustic noise, explosion proofing, and
electromagnetic interface.
2. Reliability qualification : sequential testing, life testing, environmental stress
screening (ESS) and test, analyze, and fix (TAAF).
3. Maintainability demonstration : verification of maintenance tasks, task times
and sequences, maintenance personnel quantities and skill levels, degree of
testability and diagnostic provisions, prime equipment - test equipment
interfaces, maintenance procedures, and maintenance facilities.
4. Support equipment compatibility : verification of the compatibility among the
prime

equipment,

test

and

support

equipment,

and

ground

handling

equipment.

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 Test & Evaluation.

[Blanchard, pp150 - 180]

Test & Evaluation Process.

Stages of System Testing & Evaluation.
Type testing.
5. Technical data verification : the verification and validation of operating
procedures, maintenance procedures, and supporting data.
6. Personnel test and evaluation : verification to ensure the compatibility among
the

human

and

equipment,

the

personnel

quantities

and

skill

levels

required, and training needs.

7. Software compatibility : verification that software meets the system
requirements, the compatibility between software and hardware, and that the
appropriate quality provisions have been incorporated.

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 Test & Evaluation.

[Blanchard, pp150 - 180]

Test & Evaluation Process.

Stages of System Testing & Evaluation.
Type testing.

It includes the completion of formal tests at designed field test sites by

user personnel over an extended period of time. Operating personnel,
operational test and support equipment, operational spares, applicable
computer software, and validated operating and maintenance procedures are
used.
Type testing.

It is conduced during the system operational use and life-cycle support

phase, includes formal tests that are sometimes conduced to acquire
specific information relative to some area of operation or support.

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Performance Check.
1. Preliminary logistics support is
A. The activities necessary to support a systems production and use.
B. The activities needed to assist in final deployment.
C. The preplanning of logistics support prior to the selection of the final product or
system to be selected.
D. The activities necessary to measure the impacts of logistics on an organization.

2. Preliminary system design begins with

A. A baseline configuration for the system identified and proceeds toward translating
the established system level requirements into detailed qualitative design
characteristics.
B. Only baseline configurations and does not get involved with detailed qualitative
design characteristics.
C. Systems deployment.
D. None of the above.
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Performance Check.
3. The elements included in preliminary system design include
. Functional analysis.
. Trade-off analysis.
. Linear programing.

A.

B. ,

C. , ,

D. None of the above.

4. Functional analysis involves

A. The identification of operational effectiveness.
B. The analysis of operational and maintenance factors involved in a systems
development and their translation into specific qualitative and quantitative system
design requirements.
C. An analysis of the parameters in design.
D. None of the above.
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Performance Check.
5. Specific design requirements include
. Parts selection.
. Standardization.
. Disposal capability.
. Packaging and mounting
A. , ,

B. , ,

C. , ,

D. All of the above.

6. Detailed decision begins with

A. Development of the complex system.
B. Including a configuration with performance effectiveness, logistics support, cost. and
other factors described in a system specification.
C. Validation and ends in the disposal phase of the life cycle.
D. Production and ends in the deployment phase.
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Performance Check.
7. Detailed design requires the
A. Identification of maintainability elements.
B. Simplification of human factors analysis.
C. Identification of specific elements of logistics support.
D. Determination of life cycle costs throughout the planning process.

8. Detailed design criteria are used to develop guidelines for

. Accessibility, Packaging, human factors, and life cycle costs.
. Standardization, packaging, human factors, and mobility.
. Packaging, human factors, and disposal.
A.

B.

C.

D. None of the above.

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Performance Check.
9. Detailed design requires
. The performance of trade-off studies.
. Design for supportability.
. An iterative analysis of all disposal factors before final production commences.
A.

B. ,

C. , ,

D. None of the above.

10. Design for reliability includes

. Reliability allocation, reliability models, selection of component parts, and reliability
prediction.
. Selection of components parts, models, and disposal analysis.
. Reliability analysis, models, components parts, and QFD analysis.
A.

B. ,

C. ,

D. None of the above.

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Performance Check.
11. Design for maintainability includes
. Maintainability allocation.
. Maintenance support analysis.
. Logistics support analysis.
. Deployment analysis.
A.

B. , ,

C. , ,

D. , , ,

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Performance Check.

Solutions.
1

10

11

C
- 33 -