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1 INTRODUCTION 1.1 Problem Statement and Motivation Recent experience on a jet engine development program has identified the opportunity for significant improvement in terms of cost and schedule performance during the early stages of the program. For obvious reasons, weight is a critical attribute of aircraft systems, particularly high performance military fighters. Today's business environment also demands affordability, which often conflicts with attaining low weight. Development of complex gas turbine engine control systems typically requires multiple design iterations for weight/product cost optimization and to correct technical shortfalls, resulting in significant development program cost growth and schedule risk, therefore reducing customer satisfaction. Toyota has been very successful in achieving consistently high levels of engineering quality at surprisingly low cost through the use of concurrent set-based design in which design decisions are delayed, pushing delivery of hard specifications to their suppliers until late in the process. This thesis will attempt to show the benefits of delaying design launch for turbine engine control system components whose design can be significantly affected by the uncertainty of requirement and interface definition. Put simply, "Design the engine, and then design the control system". Alternate non-flight components must be provided for initial engine test to allow development of other engine components such as software and turbomachinery and to gather test data to reduce the uncertainty of control system requirements. Causes for early design iteration are theorized and research from past development programs is presented to support these theories. Analysis is presented to support the alternate development approach. 1Ward, Allen, Jeffrey K. Liker, John J. Cristiano, and Durward K. Sobek II. "The Second Toyota Paradox: How Delaying Decisions Can Make Better Cars Faster." Sloan Management Review, Vol. 36, Issue 3 (Spring 1995), 43. 9PDF Image | Improving Gas Turbine Engine Control System
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