Representative Projects: Reliability and Maintainability (R & M)

Reliability Growth Planning for DoD Programs

Penderbrook Associates provides reliability growth program and strategy development support for DoD platform, system and equipment acquisition and reliability improvement programs. Our engineers are familiar with DoD requirements (DODI 5000.02 and Public Law 111-23) related to reliability growth planning and testing including MIL-HDBK-189, MIL-HDBK-781, and the U.S. Army Materiel Systems Analysis Activity (AMSAA) reliability growth model. This complements Penderbrook Associates reliability growth software experience, which includes use of ReliaSoft’s RGA7® reliability growth planning and assessment software tool.

Our background and experience provides us the foundation to support customers in developing reliability growth curves, plans and strategies that are integral elements of the overall test program component of the acquisitions program. Our engineers tailor each reliability growth program based on the nature of the equipment and adjust reliability growth model input parameters accordingly to develop growth curves that are realistic and attainable. We recognize reliability growth programs can be costly to implement and support our customers in developing and executing cost effective reliability growth programs that are an integral part of design and development, serve to identify and address design weaknesses early in the development cycle, meet DOTE requirements and serve to reduce overall program risk.

Signal Generator Test Set Program

The Signal Generator Test Set (SGTS) is an advanced capability, portable, aircraft radar warning receiver tester which also has the capability to conduct radio frequency performance tests on manned and unmanned aircraft.

Penderbrook Associates conducted reliability and maintainability (R&M) analyses and developed all R&M deliverables in support of the SGTS program.  

• R&M predictions were conducted using Isograph’s Reliability Workbench© software.
• R&M trade-off analyses were also conducted using Reliability Workbench© and were based on the use of alternative components in the system.
• Failure mode, effects and criticality analyses (FMECA) were conducted on SGTS using Relex© to predict failure effects and to gauge their criticality.
• A reliability test plan was developed for the SGTS using guidance from MIL-HDBK-781 and three test units were tested to demonstrate compliance with the program quantitative reliability requirement.
• A maintainability demonstration (M-Demo) plan was developed that outlined testing ground rules, test procedures and related test program details. The M-Demo applied guidance from Test Method 4 of MIL-HDBK-470A and the M-Demo also served to verify the effectiveness of troubleshooting, maintenance and corrective action procedures outlined in the draft technical manual.
• Penderbrook Associates provided support for the M-Demo test and developed the M-Demo test report which documents data collected during testing, test data analysis and results that demonstrate the design attained the quantitative mean time to repair (MTTR) requirement.

Additionally, Penderbrook Associates developed, implemented and executed a closed loop failure reporting and corrective action system (FRACAS) program that was utilized to document, track, classify and close out all failure events and incidents that occurred during developmental and qualification testing. Analyses conducted by Penderbrook engineers identified critical components that impact SGTS reliability and through the selection of more reliable components SGTS reliability was improved to enhance system readiness.

Maverick LAU-117 Dual Mode Launcher Reliability Analyses

In support of the Maverick LAU-117 Dual Mode Launcher (DML) upgrade program, Penderbrook Associates conducted reliability predictions and a failure mode, effects, and criticality analysis (FMECA) on the proposed LAU-117 design upgrade.

The project involved conducting a review of LAU-117 upgrade preliminary drawings and technical data to develop Reliability block diagrams (RBD) for the system.

• A mission profile was developed based on planned mission operational requirements and the projected operational environment the dual mode launcher will be subject to during its service life.
• Data from the mission profile was utilized in conjunction with the RBDs and the proposed bill of materials to develop a reliability prediction model in Isograph’s Reliability Workbench©.
• A FMECA was also conducted on the dual mode launcher and 250+ potential failure modes were identified.
• Sensitivity analyses were conducted to determine the impact of using alternative components, with different quality ratings and design attributes, to assess their impact on system reliability as well as FMECA classification.

As additional design details became available the reliability predictions and FMECA were updated to ensure the design remained compliant with program reliability and maintainability (R&M) requirements.

Penderbrook Associates has conducted comparable R&M analyses on a variety of systems and equipment, including:

• Aircraft BRU-55 Electric Bomb Fuzing (EBF) Power Supply
• LPD-17 Engineering Control System (ECS)
• Universal Test Set–Ground Unit for the Counter-Radio Controlled Improvised Explosion Device Electronic Warfare (CREW) System
• Mine Resistant Ambush Protected (MRAP) Vehicle
• Aircraft Enhanced Smart Triple Ejector Rack (ESTER)
• FFG-7 Class SSDG Replacement Diesel Engine
• U.S. Coast Guard Response Boat-Medium (RB-M)
• Hydraulic Start Unit (HSU)
• FFG-7 Reverse Osmosis Plant
• Broad Area Maritime Surveillance UAV Radar
• AN/SPS-67 Radar
• Auxiliary Power Unit (APU)
• DDG-51 Class SSGTG Local Operating Control Panel
• CVN-68 Class Programmable Logical Controller (PLC)
• SLEP LCAC Reliability Assessment
• U.S. Coast Guard Cutter Engineering Control System
• CG-47 Class Machinery Control System
• Universal Test Set–Hand Held (UTSHH) for the Counter-Radio Controlled Improvised Explosion Device Electronic Warfare (CREW) System
• AN-SPS 48 Radar
• UHF/VHF Receiver/Transceiver
• U.S. Coast Guard Cutter Air Conditioning Unit
• Patrol Craft Control System

Reliability, Availability and Maintainability Support to Navy Acquisition Programs

Penderbrook Associates supports the Naval Sea System Command (NAVSEA) in developing and executing reliability, availability and maintainability (RAM) programs for ship/craft and system/equipment programs. Support includes the development of RAM models to determine RAM metrics and to identify system/equipment/components primarily responsible for unavailability and unreliability. To support RAM modeling efforts, Penderbrook Associates develops mission critical system reliability block diagrams (RBD) and performs data analysis to determine system, equipment and assembly failure and repair rates as well as supportability attributes of the planned logistics support network. Results of RAM modeling are used to develop meaningful and defendable RAM requirements for use in Initial Capabilities Documents (ICD), Capabilities Development Documents (CDD) and system performance specification documents.

RAM design reference missions and mission profiles are developed based on projected operational usage scenarios extracted from requirements documents such as Concepts of Operations (CONOPS), ICD, CDD, joint operations requirements documents and other program documentation. RAM computer simulation models are developed using programs such as Raptor© and NAVSEA’s TIGER computer modeling software. The RMA computer simulation models are used to predict RAM operational performance metrics and to develop RAM quantitative requirements. Sensitivity analyses are conducted to determine the impact of varying equipment failure and repair rates, alternative designs and attributes of the support network that are envisioned to sustain the ship/craft or system. Metrics for materiel availability are developed to assess readiness of the items population based on the projected deployment concept and projected downtime periods. Materiel availability is calculated based on all projected scheduled and unscheduled maintenance including downtime associated with: preventive maintenance, planned modernization and upgrades, inspections, overhauls and corrective maintenance. Results from RAM simulation modeling efforts are utilized to develop RAM allocations for major ship/craft systems.

Penderbrook Associates supports the development of RAM sections of procurement specifications. This includes identifying the applicable RAM tasks, analyses, tests and activities to be performed during design development and testing to ensure RAM requirements are attained and to reduce program risks. Our engineers work in cooperation with system designers, system integrators, maintenance planners, test engineers, safety engineers and logisticians in developing specifications to ensure RAM requirements are coordinated with other program elements and the final specification provides for a balanced and cost effective design.  

Diesel Engine Improvement Programs

Penderbrook Associates conducts Reliability and Maintainability (R&M) analyses on shipboard propulsion and ships service diesel engine prime movers installed on Coastal Patrol Ships (PC-1 “Cyclone” Class); Mine Countermeasures Ships (MCM-1 “Avenger” Class); Dock Landing Ships (LSD 41 “Whidbey Island” and LSD 49 “Harpers Ferry” Classes); Guided Missile Frigates (FFG 7 “Oliver Hazard Perry” Class); Platform Landing Ships (LPD-17 “San Antonio” Class); and emergency diesel generator diesels installed on Nuclear Power Aircraft Carriers (CVN 68 “Nimitz” Class).

• Penderbrook developed a Material History and Metrics software tool specifically designed for conducting reliability and maintainability analyses of fielded shipboard systems that provides a common repository of fleet data, which is scrubbed, categorized and coded for analytical purposes.
• The Material History and Metrics software tool provides for efficient and effective analysis of shipboard system and equipment operational, maintenance and repair data. The automated software tool allows for a multitude of queries that arm Navy Program Managers with critical decision-making information to determine resource allocation to address reliability and cost drivers.
• Since 2004, Penderbrook Associates has processed almost 80,000 diesel engine maintenance reports from the fleet, in which the automated software tool is estimated to have saved NAVSEA approximately 5,000 labor hours over typical manual processing methods. The impact of the tool’s power in arming program managers with vital, accurate diesel engine readiness metrics in a timely manner is incalculable.
• Diesel engine operational, maintenance, inspection and repair data is analyzed to determine engine-level reliability and maintainability metrics, as well as diesel engine assembly-level failure rates.
• A variety of design engineering and preventive maintenance program improvements have been implemented on the diesel engines to improve diesel engine readiness and to reduce operating and support costs. Improvements on some ships have included replacement of the legacy diesel engines with superior diesel engines that were initiated as the result of diesel engine R&M analysis findings.
• Improvement impact assessments are conducted to project the impact of proposed improvements and to determine the effectiveness of implemented improvements.
• Results of diesel engine R&M analyses are used by Navy Program Managers to prioritize improvement program initiatives, assess the impact of implemented improvement initiatives, defend program budgets and to identify emerging failure trends.