case study: deployment of a dfss culture into the rme organization
TRANSCRIPT
05-094
Case Study: Deployment of a DfSS Culture into the RME Organization
Raytheon, Rocky Mountain Engineering (RME)Karl Arunski
This briefing is intended for those in the process of establishing a Design for Six Sigma (DfSS) culture in their organization.
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Briefing Outline
I. Introduction – The business model/environment
– The Raytheon Design for Six Sigma (DfSS) definition
– The DfSS methodology
– The DfSS training
– The DfSS deployment objective
II. Process Integration– Integrating DfSS into the business process
III. Examples
IV. Conclusions
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What We Provide(The Business Model Environment)
• Command and Control
• Mission Management
• Sensor Data Processing
Operations
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Design for Six Sigma
Raytheon Definition
“Design for Six Sigma is a methodology, used
within the Integrated Product Development
Process (IPDP), to predict, manage, and
improve Productivity, Affordability, and Robust
Performance for the benefit of our customers.”
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The DfSS Methodology
• Define key parameters
• Define objectives
• Achieve and measure– Model
– Predict
– Design
– Measure
– Iterate as required
– Achieve
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The DfSS Training Class (Outline)
• Module 1. Process Integration
• Module 2. Voice of the Customer
• Module 3. Modeling and Optimization
• Module 4. Creating and EvaluatingArchitecture Alternatives
• Module 5. Value Delivery
• Module 6. Test Optimization
• Module 7. Program Integration
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The DfSS Deployment Objective
• Predict/Manage/Improve
• “Get people to think about the methodology and to try it out.”
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II. Integrating DfSS into the Business Process
05-094-1.1
Process Integration
Voice of the Customer
Modeling and Optimization
Create and Evaluate Architecture Alternatives
Value Delivery
Test Optimization
Program Integration
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Integrating DfSS into the Business Process
05-094-2.2
Process Integration
Voice of the Customer
Modeling and Optimization
Create and Evaluate Architecture Alternatives
Value Delivery
Test Optimization
Program Integration
• Equipment Failure Analysis
• Gap analysis tool simulation/modeling• Mod and sim tool selection• AFWA DMSP MSS porting study
• FPGA development suite solution• FTN/C++ interface standards
• Make online system (test) more like Goddard Operations• EMOS analysis test cycle• Antero Program regression test
• IDMO DfSS
DfSS projects!
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Vision and Goal
• Vision– “Redesign the existing Generic Multi-purpose Board
using the most up to date technology available, while presenting the same form/fit/function to the customer.”
• Goal– Reduce the number of projected System Problem
Reports (SPRs)
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Prioritize: Defect Analysis
0
10
20
30
40
50
60
70
80
Production Engineering Vendor Handling Unknown Chassis Fail
Aurora
Valley Forge
Site
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Characterize: Production Failure Mode Effects Analysis (FMEA)
System Problem Report (SPR) Occurrences Impact
Non-Detection Score Action Plan
Poor solder flow 75 8 8 16 Parts selection criteria is surface mount where possible. Allows for WAVE solder technique.
LED failures 15 1 1 2 Selected LEDs that do not require soldering to replace; will spare these items.
Component shorts 35 5 8 13 WAVE solder will limit the occurrence of solder bridging.
Won’t download personality 65 9 1 10 Will capture in test; will not deliver any board without a personality pre-loaded.
Bad parts 14 7 7 14 Testing/over buy parts
Smoked 5 1 1 2 Testing
Short to ground (trace) 3 9 9 18 Design reviews and testing
No communication with SBC 7 6 1 7 Test/verification
Bent pins 15 1 1 2 Installation training
Voltage issues (high/low) 3 5 5 10 Complete power analysis during design. Power checks as part of TP.
Conn. Interface 24 9 9 18 New robust connectors/cables
Component failure (minor) 40 2 2 4 Over buy/test
Component failure (major) 19 5 5 10 Over buy/test
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Improve: New Architecture
05-094-4.1
General Multi-Purpose (GMP) Board Architecture Current Proposed GMPII Architecture 1
VME Interface
XCVR
DPR
uP
LBUS MBUS
FPGA
Mez Card
FrontPanel
I/O
RAMVME
Interface TUND
MPU
SDRAM
LBUS
PCI
RBUS
MBUS
FPGA
PMC Slot
DPR
FrontPanel
I/O
FLASH
A/D
I/O
VIC
FIFOs
FPGAs
PROM
NCO
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Improve: New Architecture (cont.)
05-094-5.2
Proposed GMPII Architecture 2 (selected)
VMEInterface TUND
SDRAM
LBUS
PCIBridge
RBUSMBUS
FPGA
PMC Slot
FrontPanel
I/O
FLASH
A/DandCS
I/O
MPU
DPR
1. Everything on the PCI busstandard2. Minimized the number devices on the boardless soldering3. Ball grid arrayno pins to bend4. Using surface mount partswave soldering technique5. No ribbon cables6. Micro robust connectorsfewer
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Vision and Goal
• Vision– To find new or improved methods to lower or
eliminate failures in the following items: circuit boards, swappable devices (i.e., hard drives)
• Goal– Eliminate failures
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Prioritize: Business Failure Analysis
Items That Failed
PowerSupplies
PC Boards CPUs Hard Drives Memory
Qu
anti
ty o
f F
ailu
res
Series 1
Series 2
Series 3
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Prioritize: Program A Failure Analysis
Mem
ory/E
CC
Mem
ory/D
IMM
CPUs
Power S
upply
Hard D
rives
Items That Failed
Qu
anti
ty o
f F
ailu
res
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Characterize: Fishbone Analysis
05-094-3.105-094-3.2
EquipmentFailures
Power
Vendor
Temperature
ElectrostaticDischarge
Humidity
Packing/Shipping
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Improve
• Rearchitect the environment– Temperature
– Humidity
– Power
• Procedures: electrostatic discharge requirements– Wrist straps
– ESD carts
– ESD benches
– Management involvement
– Data collection
– ESD-certified technicians replace items
– ESD improvement program
• Equipment failure analysis process– Data collection and analysis
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Vision and Goal
• Vision– “By incorporating Design for Six Sigma, the intent is
to reduce the number of Discrepancy Reports (DRs) that are written against our software.”
• Goal– Reduce the number of Discrepancy Reports (DRs)
written against the Online System
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Prioritize: Online Ops-Like Test Environment Supporting Data
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1
2
3
4
5
6
Enviro
nmen
t
Telem
etry
Cecil
Comm
and
HMI
Clock
Corr
Histo
ry
Nu
mb
er o
f D
Rs
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Prioritize: Online Ops-Like Test Environment Supporting Data
Discrepancy Report Title Category
_R0226 EMOS error message during FSW log dumps Awaiting withdrawal
_R0227 Online NCC connection anomaly CCR
_R0229 Online derived FMU/SSR telemetry points not accurate Database
_R0230 USCCS clock corr. aborts when clock error exceeds approx. 24 hours Awaiting withdrawal
_R0231 FEOF function does not seem to be working Cecil
_R0233 Access to o:\online\paves_user\ch1\misc\xxxxx.hdp denied support Integration
_R0234 CDH & COM derived points stale in eK_LA telemetry
_R0242 “Analyst” misspelled in RTLOG impacts searches/filtering Cecil
_R0261 RTM files not closed automatically History
_R0269 move_transferred_files script stopped Environment
_R0271 Auto step messages clutter commanding in central Cecil Cecil
_R0272 TES load commands padded with too many bits CCR
_T1678 Sim cfgs will not allow command if set in past Command
_R0292 Cecil waitelrv failed to catch mem load acpt flag during MCL load Cecil
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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)
Discrepancy Report Title Category
_R0293 Multi-partition TES microprocessor loads have incorrect sequence flags Command
_R0294 Error when starting transfer scripts Environment
_R0314 Error message received after GCMR proc sent Command
_R0315 EMOS RT log incorrectly indicates missing SUROM packets Awaiting withdrawal
_A0954 RBD index only shows most recent file Environment
_R0329 Suppression delta messages should be warning, not informational message
Telemetry
_R0330 Interface services died Environment
_A0958 make_intdmf_transfers. & make_history_transfers.pl died Environment
_R0335 Add limits to TES derived parameters Database
_R0344 OPS primary terminated during startup of config Clock Corr
_R0363 CH_TDRSS_INFO.dat file update for TD9 CCR
_R0369 Input derived parameters for TES RCS temperatures Database
_R0370 TES derived parameter needed for ICS motor current Database
_R0376 TES time fields differ between online and MMS Command
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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)
Discrepancy Report Title Category
_R0387 MLS temperatures are stale Telemetry
_R0388 Unused MLS derived parameters still in online system Database
_R0402 1750a mnemonics not alarming Telemetry
_R0406 TLM page cell can be “Frozen” with alarm state format HMI
_A0999 RDD clock correlation report files deleted Clock Corr
_R0462 ESRS12 fell off talarian Investigating
_R0493 Delete red limits for GNC mnemonics Database
_R0511 EMOS suppression delta detection incorrect Telemetry
_R0512 Incorrect time tag in real time log Investigating
_R552 AQUA telem decommed by AURA EMOS system CCR
_R0535 GNC star tracker voltage derived mnemonics are incorrect Database
_R0545 Plots show “No Updates Yet” HMI
_R0555 Ground config failed to start on EORS12 Investigating
_R0556 Remove yellow limits from SUROM secondary test derived tlmy pts Database
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Characterize: Root Cause Analysis Results
• Not enough “ops like” testing procedures
• Not enough testing done by different users’ logins
• Not keeping interfaces running regularly
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Improve: Create a More Ops-Like Environment
• Update the “on-line” test procedures
• Implement ops-like procedures
• Test using several different user-name logins
• Keep interfaces running regularly
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Enviro
nmen
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Telem
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Cecil
Comm
and
HMI
Clock
Corr
Histo
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Nu
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Achieve
No Discrepancy Reports!