Logistics Engineering & Management

FOREWORD ix PREFACE xi 1. INTRODUCTION TO LOGISTICS 1(45) 1.1 The Current Environment 2(2) 1.2 The Scope of Logistics 4(7) 1.3 The Elements of Logistics 11(4) 1.4 Logistics in the System Life Cycle 15(6) 1.5 Performance-Based Logistics (PBL) 21(3) 1.6 The Need for Logistics Engineering 24(3) 1.7 Related Terms and Definitions 27(17) 1.7.1 System Engineering 28 1.72 System Analysis 30(1) 1.7.3 Supportability Analysis (SA) 30(2) 1.7.4 Concurrent/Simultaneous Engineering 32(1) 1.7.5 Software Engineering 32(1) 1.7.6 Reliability (R) 33(1) 1.7.7 Maintainability (M) 34(1) 1.7.8 Maintenance and Support 35(2) 1.7.9 Human Factors (Ergonomics) 37(1) 1.7.10 Safety and Security 37(2) 1.7.11 Producibility 39(1) 1.7.12 Disposability 39(1) 1.7.13 Configuration Management (CM) 39(1) 1.7.14 Total Quality Management (TQM) 40(1) 1.7.15 System Effectiveness (SE) 40(2) 1.7.16 Life-Cycle Cost (LCC) 42(1) 1.7.17 Cost-Effectiveness (CE) 43(1) 1.8 Summary 44(1) Questions and Problems 44(2) 2 RELIABILITY, MAINTAINABILITY, AND AVAILABILITY MEASURES 46(32) 2.1 Reliability Measures and Related Factors 47(11) 2.1.1 Reliability Function and Failure Rate 47(5) 2.1.2 Reliability Models and Component Relationships 52(6) 2.2 Maintainability Measures and Related Factors 58(14) 2.2.1 Maintenance Elapsed-Time Factors 58(10) 2.2.2 Maintenance Labor-Hour Factors 68(2) 2.2.3 Maintenance Frequency Factors 70(2) 2.2.4 Maintenance Cost Factors 72(1) 2.3 Availability Factors 72(1) 2.3.1 Inherent Availability (Ai) 72(1) 2.3.2 Achieved Availability (Aa) 73(1) 2.3.3 Operational Availability (A0) 73(1) 2.4 Summary 73(1) Questions and Problems 74(4) 3 THE MEASURES OF LOGISTICS AND SYSTEM SUPPORT 78(45) 3.1 System Measures of Effectiveness (MOEs) 78(11) 3.1.1 System Effectiveness (SE) 79(2) 3.1.2 Economic and Life-Cycle Cost (LCC) Factors 81(6) 3.1.3 Cost-Effectiveness (CE) 87(2) 3.2 Supply Chain Factors 89(3) 3.3 Purchasing and Material Flow Factors 92(2) 3.4 Transportation, Packaging, and Handling Factors 94(5) 3.5 Warehousing and Distribution Factors 99(2) 3.6 Maintenance Factors 101(16) 3.6.1 Organizational Factors 101(1) 3.6.2 Spares, Repair Parts, and Related Inventory Factors 102(11) 3.6.3 Test and Support Equipment Factors 113(1) 3.6.4 Transportation and Materials Handling Factors 114(1) 3.6.5 Maintenance Facility Factors 115(1) 3.6.6 Computer Resources and Maintenance Software Factors 115(1) 3.6.7 Technical Data and Information System Factors 116(1) 3.7 System Retirement and Material Recycling/Disposal Factors 117(1) 3.8 Summary 117(2) Questions and Problems 119(4) 4 THE SYSTEM ENGINEERING PROCESS 123(68) 4.1 Definition of Problem, and Needs Analysis 125(2) 4.2 System Feasibility Analysis 127(1) 4.3 System Operational Requirements 128(11) 4.4 Maintenance and Support Concept 139(7) 4.5 Identification and Prioritization of Technical Performance Measures (TPMs) 146(4) 4.6 Functional Analysis 150(12) 4.6.1 Functional Flow Block Diagrams (FFBDs) 154(1) 4.6.2 Operational Functions 155(1) 4.6.3 Maintenance and Support Functions 156(1) 4.6.4 Application of Functional Flow Diagrams 157(5) 4.7 Requirements Definition and Allocation 162(11) 4.7.1 Allocation of Reliability Requirements 163(6) 4.7.2 Allocation of Maintainability Requirements 169(3) 4.7.3 Allocation of Logistic Support Requirements 172(1) 4.7.4 Allocation of Economic Factors 172(1) 4.8 System Synthesis, Analysis, and Design Optimization 173(7) 4.9 System Test and Evaluation 180(7) 4.10 Summary 187(1) Questions and Problems 188(3) 5 LOGISTICS AND SUPPORTABILITY ANALYSIS 191(65) 5.1 The Analysis Process 193(11) 5.2 Analysis Methods and Tools 204(36) 5.2.1 Life-Cycle Cost Analysis (LCCA) 204(7) 5.2.2 Failure Mode, Effects, and Criticality Analysis (FMECA) 211(5) 5.2.3 Fault-Tree Analysis (FTA) 216(5) 5.2.4 Maintenance Task Analysis (MTA) 221(6) 5.2.5 Reliability-Centered Maintenance (RCM) 227(5) 5.2.6 Level-of-Repair Analysis (LORA) 232(5) 5.2.7 Evaluation of Design Alternatives 237(3) 5.3 Supportability Analysis Applications 240(3) 5.4 Logistics Management Information (LMI) 243(3) 5.5 Summary 246(1) Questions and Problems 246(10) 6 LOGISTICS IN SYSTEM DESIGN AND DEVELOPMENT 256(63) 6.1 The Design Process 257(16) 6.1.1 Conceptual Design 257(1) 6.1.2 Preliminary System Design 258(1) 6.1.3 Detail Design and Development 259(14) 6.2 Related Design Disciplines 273(28) 6.2.1 Design for Reliability 273(8) 6.2.2 Design for Maintainability 281(4) 6.2.3 Design for Human Factors and Safety 285(7) 6.2.4 Design for Producibility 292(1) 6.2.5 Design for Quality 293(2) 6.2.6 Design for Disposability 295(1) 6.2.7 Design for Economic Feasibility 296(3) 6.2.8 Design for the Environment 299(2) 6.3 Supplier Design Activities 301(1) 6.4 Design Integration, Design Review, and System Evaluation 302(8) 6.5 System Test and Evaluation (Validation of the Logistics and Support Infrastructure) 310(3) 6.6 Design Changes and System Modifications 313(2) 6.7 Summary 315(1) Questions and Problems 316(3) 7 LOGISTICS IN THE PRODUCTION/CONSTRUCTION PHASE 319(31) 7.1 Production/Construction Requirements 320(7) 7.2 Industrial Engineering and Operations Analysis 327(5) 7.3 Production/Manufacturing Operations 332(3) 7.4 Quality Control 335(4) 7.5 Measurement and Evaluation of Production Capability 339(1) 7.6 Transition from Production to Customer (User) Operations 340(5) 7.7 Summary 345(1) Questions and Problems 346(4) 8 LOGISTICS IN THE SYSTEM UTILIZATION, SUSTAINING SUPPORT, AND RETIREMENT PHASES 350(22) 8.1 System Support Requirements 351(2) 8.2 Assessment of Logistics Capability 353(14) 8.2.1 Data Collection, Analysis, and Reporting 353(5) 8.2.2 Evaluation of Logistics Elements 358(9) 8.3 System Modifications 367(1) 8.4 System Retirement 368(1) 8.5 Summary 369(1) Questions and Problems 369(3) 9 LOGISTICS MANAGEMENT 372(61) 9.1 Logistics Program Planning 373(14) 9.1.1 Logistics in the System Life Cycle 373(4) 9.1.2 Development of Specifications 377(2) 9.1.3 Development of Planning Documentation 379(8) 9.2 Development of a Work Breakdown Structure (WBS) 387(1) 9.3 Scheduling of Logistics Tasks 388(10) 9.4 Cost Estimating and Control 398(2) 9.5 Major Interfaces with Other Program Activities 400(4) 9.6 Organization for Logistics 404(24) 9.6.1 Customer, Producer, and Supplier Relationships 405(1) 9.6.2 Customer Organization and Functions (Consumer) 406(1) 9.6.3 Producer Organization and Functions (Contractor) 407(15) 9.6.4 Supplier Organization and Functions 422(3) 9.6.5 Staffing the Organization 425(3) 9.7 Management and Control 428(2) 9.8 Summary 430(1) Questions and Problems 431(2) APPENDIX A: SELECTED BIBLIOGRAPHY 433(10) APPENDIX B: SYSTEM DESIGN REVIEW CHECKLIST 443(15) APPENDIX C: SUPPLIER EVALUATION CHECKLIST 458(7) APPENDIX D: LIFE-CYCLE COST ANALYSIS (LCCA) 465(31) APPENDIX E: MAINTENANCE TASK ANALYSIS (MTA) 496(24) APPENDIX F: SELECTED INTEREST TABLES 520(11) APPENDIX G: NORMAL DISTRIBUTION TABLES 531(3) APPENDIX H: ABBREVIATIONS 534(4) INDEX 538