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Balancing Lifecycle Sustainment Cost with Value of Information during Design Phase

CCDC Ground Vehicle Systems Center-Sam Kassoumeh, Monica Majcher, James Ealy, David Gorsich, Paramsothy Jayakumar
Oakland University-Vijitashwa Pandey
  • Technical Paper
  • 2020-01-0176
To be published on 2020-04-14 by SAE International in United States
The complete lifecycle of complex systems, such as ground vehicles, consists of multiple phases including design, manufacturing, operation and sustainment (O&S) and finally disposal. For many systems, the majority of the lifecycle costs are incurred during the operation and sustainment phase, specifically in the form of uncertain maintenance costs. Testing and analysis during the design phase, including reliability and supportability analysis, can have a major influence on costs during the O&S phase. However, the cost of the analysis itself must be reconciled with the expected benefits of the reduction in uncertainty. In this paper, we quantify the value of performing the tests and analyses in the design phase by treating it as imperfect information obtained to better estimate uncertain maintenance costs. A multi-attribute decision framework for military ground vehicles acquisition is employed to illustrate the methodology and the value of performing the analysis early in the system’s lifecycle. Attributes considered are maintenance cost and operational availability, while the utility is calculated for a risk averse decision maker. Numerical methods are employed to calculate the value…

Root Cause Problem Solving: Methods and Tools

  • Professional Development
  • C1053
Published 2020-02-06
2 Days 1.3 CEUs
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Thread Inspection Practices

E-25 General Standards for Aerospace and Propulsion Systems
  • Aerospace Standard
  • AS5870
  • Current
Published 2020-02-03 by SAE International in United States
This document addresses AS8879 thread inspection issues relating to selection, usage and capability of gages. It addresses the selection of calibrated measurement gages, the need for defined quality metrics, the methodology of determining the appropriate guardband factors, and the minimum inspection requirements for single element pitch diameter gages. Users of this document shall apply the information described herein for the evaluation of the capability of their measurements based on the measurement consumer risk. It involves the analysis of the measurement (product) distribution and biases of both the product and measurement system distributions. It protects the consumer from the worst case distribution results. A whitepaper has been developed to provide supporting documentation and the rationale used in the development of this standard. This whitepaper will be published by the SAE as an Aerospace Information Report (AIR6553). This document recommends the use of ASME B1.2 “Gages and Gaging for Unified Inch Screw Threads” or IFI 301 “Gage Calibration Requirements and Procedures for Thread Gages” as guides for establishing the minimum calibration requirements for all types of thread…
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Risk Management Throughout the Automotive Development Process Web Seminar RePlay

  • Webinar Recordings
  • PD331629
Published 2019-11-19
No Abstract Available.
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A Framework for Effective Implementation of Process Failure Modes and Effects Analysis with Control Plans to Mitigate Process, Discrete Manufacturing and Service Industries, Using Aerospace Standard Best Practices

GITAM School of Technology-Mani Rathinam Rajamani, Eshwaraiah Punna
Published 2019-10-11 by SAE International in United States
In Today’s World, Every Manufacturing and Service Industry aims in providing the Highest Quality of Products and Service at the lowest Competitive Cost and timely delivery to its Customers. The Discrete Aerospace Manufacturing and Assembly industry is taking initiatives to implement the Process Failure Modes and Effects Analysis (PFMEA) tool for its critical Aerospace Manufacturing and Assembly suppliers, by implementing Aerospace Standards, in an effort to create a synergy between the End user customers, Original Equipment manufacturers and the suppliers, for ensuring increased safety, quality, reliability for the Aircraft parts and components produced by them. The main aim is to use this concept as a Process Risk Management tool for Identification, Assessment, Mitigation, Control and Prevention of risks associated with Designs and Manufacturing. This method is quite different from conventional FMEA methodology as it focuses on an integrated approach of linking the process flow diagram, followed by a PFMEA again linked with a Control plan to identify and implement controls for measuring and monitoring the process risks. This can identify the manufacturing system’s area of…
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Safety Assessment of General Aviation Airplanes and Rotorcraft in Commercial Service

S-18C ARP5150A and ARP5151A Working Group
  • Aerospace Standard
  • ARP5151A
  • Current
Published 2019-08-20 by SAE International in United States
This document describes a process that may be used to perform the ongoing safety assessment for (1) GAR aircraft and components (hereafter, aircraft), and (2) commercial operators of GAR aircraft. The process described herein is intended to support an overall safety management program. It is to help a company establish and meet its own internal standards. The process described herein identifies a systematic means, but not the only means, to assess continuing airworthiness. Ongoing safety management is an activity dedicated to assuring that risk is identified and properly eliminated or controlled. The safety management process includes both safety assessment and economic decision-making. While economic decision-making (factors related to scheduling, parts, and cost) is an integral part of the safety management process, this document addresses only the ongoing safety assessment process. This ongoing safety assessment process includes safety problem identification and corrective action, tracking of problems, the application of “lessons learned” to improve the efficiency of the process, and reduction of the time to achieve corrective action in the field. ARP5150 is the recommended practice for…
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Aircraft Ground Deicing/Anti-Icing Training and Qualification Program

G-12T Training and Quality Programs Committee
  • Aerospace Standard
  • AS6286A
  • Current
Published 2019-06-26 by SAE International in United States
This document establishes the minimum training and qualification requirements for ground-based aircraft deicing/anti-icing methods and procedures. All guidelines referred to herein are applicable only in conjunction with the applicable documents. Due to aerodynamic and other concerns, the application of deicing/anti-icing fluids shall be carried out in compliance with engine and aircraft manufacturers’ recommendations. The scope of training should be adjusted according to local demands. There are a wide variety of winter seasons and differences of the involvement between deicing operators, and therefore the level and length of training should be adjusted accordingly. However, the minimum level of training shall be covered in all cases. As a rule of thumb, the amount of time spent in practical training should equal or exceed the amount of time spent in classroom training.
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New Half Shaft Bench Test Methodology for NVH Characterization

FCA US LLC-Wei Yuan, Ahmad Abbas, Francisco Antonio Sturla
Siemens PLM Software-Saeed Siavoshani, Prasad Balkrishna Vesikar
Published 2019-06-05 by SAE International in United States
The main purpose of this paper is to develop a reliable bench test to understand the vibratory behavior of the half shafts under applied torque comparable to an idle condition. In some cases, the half shaft path is a major factor influencing the idle vibration in the vehicle. At idle condition vehicle vibrations are caused by engine excitation and then they pass through different paths to the body structure. Half shaft manufacturers generally characterize shaft joints for their frictional behavior and typically there is no data for vibration characteristics of the half shaft under idle conditions. However, for predictive risk management, the vibratory behavior of the half shaft needs to be identified. This can be achieved from measured frequency response functions under preloaded test conditions.This bench test enables manufacturers to conduct comprehensive design of experiments on the impact of powertrain vibration input while transmitting through the half shaft into the vehicle system. This method enables the study of the half shaft at the component level, because studying the half shaft at vehicle level is difficult…
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Strategies for Low-Risk Sourcing of Components in a Constrained Market

  • Magazine Article
  • TBMG-34562
Published 2019-06-01 by Tech Briefs Media Group in United States

The medical device industry often looks to independent distributors to address chronic shortages in the availability of electronic components. Direct sourcing of electronic components for the medical device industry used to be pretty simple. An OEM would order direct from the manufacturer or through authorized distributors to obtain any required components. There was usually no need to look any further.

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SAE ARP6338: Process for Assessment and Mitigation of Aging and Potential Early Wearout of Life-Limited Microcircuits (LLM)

SAE International Journal of Advances and Current Practices in Mobility

DfR Solutions-Lloyd Condra, Ashok Alagappan, Craig Hillman
  • Journal Article
  • 2019-01-1254
Published 2019-04-02 by SAE International in United States
This paper describes a Reliability Physics Analysis process to assess aging and the potential for early wearout of microcircuits, as documented in SAE ARP6338. As microcircuit feature sizes (gate length, line width, etc.) continue to shrink to near atomic levels, they become increasingly susceptible to aging mechanisms such as Electromigration, Time-Dependent Dielectric Breakdown, Hot Carrier Injection and Bias Temperature Instability effects. These mechanisms are driven by voltage, current and thermal operating stresses resulting in shorter times for aging to progress to the point where wearout can occur. If the times to wearout are shorter than the required lifetimes of the microcircuits in their applications, the microcircuits are called Life-Limited Microcircuits. A brief overview of these aging mechanisms and their impact on the long-life electronics systems used in Aerospace, Automotive, Defense, and other High Performance industries is provided. A summary of the SAE ARP6338 approach and implementation recommendations is also provided along with its importance to automotive Advanced Driver-Assistance Systems and autonomous electronic systems.
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