System integration analysis of a large commercial aircraft engine

Abstract

In this thesis we develop and demonstrate a method, called a System Integration Analysis, to produce a comprehensive understanding of the activities Integrated Product Teams (IPTs) perform in designing and developing a large complex product or system. The methodology is applied to an existing product or system whose physical architecture can be partitioned into comparable sections, or chunks, as the IPTs who design and develop it. Its goal is to identify specific integrative mechanisms to better align the Integrated Product Development (IPD) process and the organization with the product architecture. These mechanisms are then developed into specific recommendations in consideration of a strategic and tactical framework for achievement of the desired future state of the organization and its IPD process. Implementation of the initiatives is directed to a comprehensive change process defined to address the cultural, structural, and political reality of the company. The methodology uses two distinct applications of a Design Structure Matrix, and several complimentary approaches to the analysis of the data. The methodology is demonstrated with a world-class commercial high bypass-ratio turbofan engine, the Pratt & Whitney PW4098. This product is a derivative design of an existing configuration, or family of engines. Recommendations based upon the PW4098 application include specific interface management and system integration improvements, a minor organizational re-alignment, stronger discipline management, and clearly defined roles and responsibilities of key players.