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MEC 8910A

WORKFLOWHOW TO SUCCESSFULLYCOMPLETE A PROJECT IN

AERONAUTICAL INDUSTRY

Lecture 6

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LECTURE 5 RECAP PRE-DESIGN ENGINEERING PACKAGES & DRAWINGS

APPROVAL CYCLE PROCUREMENT

DESIGN REVIEWS

DEVELOPMENT REMOVAL

MANAGING CHANGES

TYPE BOARD REVIEWS (initial, interim & final)

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SOURCE SELECTION &

QUALIFICATION

Outsourcing

decision

ENGINEERING

Procurement Specification (PS),

Source Control Drawing (SCD) or

Technical Requirements

Document (TRD) release & vendor

SOW update with required

CDRLs listing & due dates

PROCUREMENTsend RFQ to vendors

with due date & submit

quotes to engineering

for technical review

Preliminary Source

Selection meeting

Engineering

Detailed technical data

review & evaluation

Engineering &

Procurement

Technical Negotiations

Procurement

& Vendors

Memorandum of

Agreement

Final Evaluation

meeting

Source

selection

CDRLs

Delivery,

data review &

certification testing

Vendorapproval

Qualified Parts &

Vendors List database

update

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LECTURE 5 RECAP PRE-DESIGN

ENGINEERING PACKAGES & DRAWINGS

APPROVAL CYCLE

PROCUREMENT

DESIGN REVIEWS

DEVELOPMENT REMOVAL

MANAGING CHANGES


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DESIGN REVIEWS Design reviews are an essential quality

assurance tool in achieving a project withincost & schedule.

It has many objectives such as:

Validation of the design requirements against thecertification basis and the customer requirements

Early detection of required design changes

Early detection of risk areas

Enable junior engineers to benefit from experienceof the senior engineers

Third party review of the work done

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DESIGN REVIEWS Typical Commercial Design Reviews

Statement of Work Review (SOWR)

Preliminary Design Review (PDR)

Critical Design Review (CDR)

Other Military Type Design Reviews SRR System Requirements Review

SDR System Design Review

SSR Software Specification Review

TRR Test Readiness Review FRQ Formal Qualification Review (same as

Commercial Type Board Meeting)

PRR Production Readiness Review

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Define Requirements & Risks

Develop Concept & Risk Mitigation

Pre-design Definition

Design & Develop

Prototyping

Product Validation

Gate 1

Gate 2

Gate 3

Gate 4

Gate 5

SOWRSOWR

SRRSRR

PDRPDR CDRCDR

TRRTRR FQRFQR

PRRPRR

SDRSDR

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DESIGN PHASE PRE-DESIGN


APPROVAL CYCLE

PROCUREMENT

DESIGN REVIEWS

DEVELOPMENT REMOVAL

MANAGING CHANGES


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DEVELOPMENT REMOVAL While EMU use significantly reduces aircraft

reworks, often first installation will revealdesign change requirements such as design

oversights or tolerance stack up problems. This first installation is typically referred to as

the development removal, were engineering,

manufacturing, planning & quality assurancedepartments through associated effortsresolve all installation & functionality issues.

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APPROVAL CYCLE

PROCUREMENT

DESIGN REVIEWS

DEVELOPMENT REMOVAL

MANAGING CHANGES


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MANAGING CHANGES

Your ultimate goal is to minimize changes,do the right thing the first time.Unfortunately, the larger the project is thechanges are more or less inevitable.

There are basically two types of changes:

Scope changesDesign changes

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SCOPE & DESIGN CHANGES Scopes changes

These are new requirements; additional budgetrequired over the initial authorized budget.

Examples for Bell 429EP could be because customer asks

for Emergency flotation system.

Inlet barrier filter

Category A Performance

Design changes

Modifications to make it work and/or to make itcertifiable; must be absorbed within the authorizedbudget.

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SCOPE CHANGES(Potential Examples from Bell

429EP)

Emergency

Flotation

System

Category A

Performance

Inlet Barrier

Filter

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SCOPE CHANGES

Define the new requirements and identifyupdates required to the SOW.

Assess impact on the baseline SOW &certification basis and estimate time & costimplications of the new requirements.

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SCOPE CHANGES

Submit to management for additional budget& schedule change approval

Do not start the work until it is approved

Delays in getting additional approval mayhave impact on cost & schedule; submit atime phase approval schedule. If approvedwithin two weeks - $45,000 & 2 weeksdelay, if approved within one month -$180,000 & 5 weeks delay.

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DESIGN CHANGES Often needed to deliver an acceptable &

functional product. Once again, they arealmost inevitable.

Due most to unanticipated or changedconditions:

More specific knowledge

Actual conditions

Rework

New Technology

Regulatory Agency regulations interpretation

Change of personnel

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DESIGN CHANGES

Eats up contingency funds & projectschedule buffers very fast, be careful!!!

Early detection of required design changeswill minimize cost & schedule implications.

Proper planning, right cert. basis

identification, good communication, propertechnical supervision (design reviews) areall conducive to doing it right the first time.

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APPROVAL CYCLE

PROCUREMENT

DESIGN REVIEWS

DEVELOPMENT REMOVAL

MANAGING CHANGES


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TYPE BOARD REVIEWS Type Board meetings (Initial, Interim & Final)

also part of the design validation processagainst the approved certification basis.

These meetings are held with the following

respective objectives: To present the intended aircraft configuration and

Certification Plan & Certification Basis approval.

To present project status and resolve outstanding

certification issues (i.e. Issue Papers). To finalize certification issues and obtain TC or

STC approval.

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PROJECT EXECUTION ENGINEERING EFFORT

DESIGN PHASE

PROTOTYPES & DEVELOPMENT FLIGHT

TESTING

CERTIFICATION TESTING

COST & SCHEDULE TRACKING

TRANSPORT CANADA APPROVAL

TYPE BOARD REVIEWS

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NP&SI PROCESS SUMMARY

PHASE 1: Define Requirements & Risks

PHASE 2: Develop Concept & Risk Mitigation

PHASE 3: Pre-design Definition

PHASE 4: Design & Develop

PHASE 5: Prototyping

PHASE 6: Product Validation

PHASE 7: Transition to Manuf/Service

Gate 1

Strategic

Plan Input

Deliverables Defined

and completed beforeleaving each Gate

Gate 2

Gate 3

Gate 4

Gate 5

Gate 6

Gate 7

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PROTOTYPES Prototype aircraft are used throughout the

development testing & certification testing phase.Can be manufactured faster and will never have a

C of A.

These aircraft are typically not entirely productionaircraft representative. consequently, they can onlybe used for certification testing where a similarityargument can be accepted by the regulatory agency.

Requires Aircraft Limitations Report & experimental flight

test permit approval

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DEVELOPMENT TESTING

This testing phase is to explore the targetflight envelope, identify problem areas &safety margins. It can also include

certification testing dry runs.

Problem areas are assessed and resolvedthough aircraft configuration changes,

engine and/or transmission performanceincrease or aircraft limitations acceptance.

May require re-testing

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DEVELOPMENT TESTING

New Rotor

Ground resonance / Aeromechnical /Torsional Stability

Loads Performance

Handling Qualities (HQs)

Engine / drive system vibrations

Ride quality (FRAHMS)

AFCS

Initial cut at gains / scheduling

Autopilot Development

Flight Director Development

Prototype to Support Development Testing:

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DESIGN PHASE

PROTOTYPES & DEVELOPMENTFLIGHT TESTING




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Certification testing, delegated or not, isconducted to show satisfactorycompliance to regulations within definedparameters.

Aircraft configuration conformity inspection

per to test plan requirements is to becompleted prior to test start.

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CERTIFICATION TESTING When the test is not delegated, the

regulatory agency will often conduct testplan matrix spot check or perform specifictest areas then delegate the remaining ofthe tests to the DAO.

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For both development & certificationtesting, some tests are dependent on

specific temperature, density altitudeand/or wind conditions. It may generateoff-site testing requirements and/or delayswaiting for the right conditions.

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CERTIFICATION TESTING(Example Flight Tests for the New 429EP)

Load Level Survey

Hot Weather

Engine Vibration

Drive Shaft Vibration

Torsional Vibration Engine Cooling

Tailboom Temperature Survey

Hot Fuel

Oil System Test

Inlet Distortion Inlet Icing

Handling Qualities

Performance

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CERTIFICATION TESTING(Example Flight Tests for the New 429EP)

Tail Rotor Flapping

Cat A Runway

Cat A Ground Helipad

Noise Survey

Autopilot Certification

Controls Proof Load

Indirect Lightning

Cold Soak

Cockpit Cooling

Cockpit Lighting EMI / EMC

Avionics System

Function & Reliability (F&R)

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DESIGN PHASE





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Rigorous cost & schedule trackingthroughout its duration is most important in

any projects, it may seriously affect designchanges decisions.

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COST & SCHEDULE TRACKING Cost tracking by WBSE is done by comparing

the following values: Planned to date: $ 45,000

Actual to date: $ 55, 000

Budget: $ 165,000 Estimated at completion $ 185,000

Variance (-$20,000)

Your contingency is busted and some other WBSE

contingency budgets will need to absorb it. If higheractuals were due to a scope change, the budgetwould require an increase with zero value variance.

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Schedule tracking is done using a baselineGantt chart with regular updates to reflectactuals.

A (6 days)A (9 days)

BaselineActuals, late finish,

schedule delays & nocost impact

(3 days added)

Late start

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PROJECT EXECUTION

ENGINEERING EFFORT

DESIGN PHASE





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TCAC INVOLVEMENT Regulatory Agencies involvement, not limited

but coordinated through TCAC, throughoutthe planning & the execution phase of theprogram is essential to avoid missing out

certification requirements.

It may cause delays but it certainly reducesrisks and reworks.

Communication with regulatory agency is tobe done through the OEM/DAO Airworthinessdepartment or through the company CDs.

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TCAC INVOLVEMENT For example, a Canadian OEM has just

obtained its TC with TCAC on a new aircraftmodel. One of its first customers is US

operator which must operate its aircraft underUS registry. During the FAA TC validationprocess, FAA decides to impose specialconditions on a particular aircraft system that

necessitate major design change. OEM inturn may lose this sale and potentially a widemarket share until it incorporates the change.

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TCAC INVOLVEMENT

CDs should maintain weekly, if not daily,contacts with their TCAC counterpart tokeep them abreast of project development

and/or to obtain a concession/concurrenceon technical issue.

Any CD & TCAC specialist verbalagreement is to be documented (contact

report), submitted to TCAC specialist forvalidation and distributed to all involved.

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Gate 1

Strategic

Plan Input



Gate 2

Gate 3

Gate 4

Gate 5

Gate 6

Gate 7

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PRODUCTION Factors affecting the certificated aircraft

configuration and documentation onceproduction commences can include

Modifications to the design due to The prototype aircraft were not 100%

representative of final production standard

Production easement Quicker, cheaper, fewer

parts Component reliability less than expected

New requirements: customer, foreign certification

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POST-CERTIFICATION Factors affecting the certificated aircraft

configuration and documentation post-certification include

Modifications to the design due to

In-service failures

Environmental factors

Aging aircraft

Changes to the operating and crew procedures

Maintenance tasks and their periodicity Allowable deficiencies (MMEL Master Minimum

Equipment List)

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CHANGED PRODUCT RULE

Why was Changed Product Rule introduced? To make major design changes and derivatives of older

aircraft e.g. Boeing 737 comply with the same airworthinessstandards as new designs of aircraft e.g. Airbus A320.

What happened before CPR?

Before CPRWhen a design change to an existingaeronautical product was introduced the amendment level ofthe regulations was the same as the original TC.

So the Boeing 737 derivatives (737-200, -300, -400, -500,-600, -600NG, -700, -800 and 900 were all certificated tothe same amendments as applied to the original 737 aircraft,

decades before !! The new Airbus A320, a similar aircraft to the 737, had to be

certificated to the latest amendments of the regulations.

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Substantial Change

Section 511.14 and 513.14 of the CARs

require that an applicant obtain a new type

certificate if the scope and nature of theproposed change in design, configuration,

power, power limitations (engine), or

weight are so extensive that a substantially

complete investigation of compliance withthe applicable standards is required.

(Source: AC 500-016)

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Substantial Change

The OEM must apply for a new TypeCertificate if the change in design, power,

thrust or weight is extensive. For example: Change from a high wing to a low wing, or vice-versa

Change of empennage configuration (from cruciform toT-tail)

Overall power/thrust increase of more than 50%

Change in flight control concept, i.e. change to fly-by-wire

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Significant ChangeAdditionally, subsection 511.13(3) and 513.07(3) of the CARs

define a significant change based on whether or not one or

more of the three criteria applies:

(a) the general configuration is not retained;(b) the principles of construction are not retained; and

(c) the assumptions used for certification of the product do

not remain valid. In many cases, a significant change will

involve more than one of these criteria and will, by its

very nature, be obvious and distinct from other productimprovements or production changes.

(Source: AC 500-016)

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Significant Change

The OEM must use the latest amendmentlevel (unless its impractical and/or no

impact on safety !!) if the change issignificant. For example: Change in fuselage length or diameter

Change in wing sweep angle of

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How do we decide if we have aSubstantial or Significant change?

Transport Canada has published an

Airworthiness Manual Advisory AC 500-016 to help us decide

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FINAL EXAMINATIONWhat we have covered ...What we have covered ...

Types of requirement

Abbreviation & definition

NP&SI Process Risk & Contingency

Functional Hazard Analysis Criticalities

System Safety Analysis Fault Tree Analysis

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TYPES OF REQUIREMENT: ABBREVIATIONS & DEFINITION

TYPE DESIGN & TYPE CERTIFICATE

SUPPLEMENTAL TYPE CERTIFICATE (STC)

FAR, CAR, EASA, JAR, OEM, AC

IPT, NP&SI PROCESS

SPECIAL CONDITION

NPRM

EXEMPTION

EQUIVALENT LEVEL OF SAFETY

TSO

ICAO DAO, CD (DER)

CERTIFICATION BASIS & GENERAL COMPLIANCE PLAN (GCP)

DOC, NPV, ROIC, IRR

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Gate 1

Strategic

Plan Input



Gate 2

Gate 3

Gate 4

Gate 5

Gate 6

Gate 7

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CERTIFICATION

Originalapproval ofan aircraft

design

Approval of amanufacturers QCsystem to produce

aircraft that replicate theapproved design

Approval of an individualaircraft that conforms to the

type design and is in acondition for safe operation

Monitoring safetyperformance of

approved product,production QCsystem & taking

corrective action toensure continued

integrity

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Functional Hazard Assessment

Source: SAE ARP 4761

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FINAL EXAMINATION

What we have covered What we have covered

Development Removal

Managing Changes

Prototype & Development Testing

Transport Canada Approval

Production

Post-Certification (Changed Product Rule)

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CLOSING REMARKS

Anyquestions?Anyquestions?

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