High complex product development : a framework for flight test campaign optimization
Author
Edmar Thomaz da Silva
Advisor
- Advisor Luís Gonzaga Trabasso
Concentration Area
Sistemas Aeroespaciais e Mecatrônica
Defense Date
10/12/2015
Thesis Number
69916
Abstract
Although the main aeronautical industries use best practices associated with the development of complex products, all major developments of the last decade were marked by delays in deadlines, budgets additives as well as, problems associated with the perception of quality of the product caused by fault identification by the client at entry into service. On the other hand, considering the integrated product development process, the testing phase is the last stage before obtaining type certificate (TC). In this context, the Flight Test Organization is pressed to produce the results as soon as possible in order to compensate for the delays of previous phases. In 2005, a diagnostic study conducted at Embraer showed that most of the certification requirements are demonstrated through flight testing and a smaller portion with other means (modeling and simulation, ground testing, analysis, similarity etc). The Integrated Product Development (IPD) process is so centered on flight testing. However, flight tests are the most expensive means to demonstrate compliance with the requirements and corrections of design flaws. There is a paradoxical situation where one is trying the cost reduction using the most expensive and highest cycle mean to facilitate this strategy. This work will revisit the concepts and tools used for the development of complex products, identify the main problems associated with aeronautical development processes and their campaigns. From a vision of complementarity of the various tools, will propose a new approach to optimize the flight testing campaigns. The optimization occurs by the transfer of the development effort of flight tests for ground testing and for modeling and simulation. The new strategy will be instantiated in two relevant topics associated with aircraft development: the systems integration and flight test campaign to demonstrate aircraft performance
