Lessons learned from the F-22 avionics integrity program

The F-22 is contractually required to be significantly more reliable than the F-15C/D. Prior to the Gulf War, the F-15 C/D's Mean Time Between Maintenance (MTBM) total was 0.6 hours. The F-22's MTBM (total) requirement is 3.0 hours. This required improvement in maintenance demand is based on improvements in equipment reliability. This high reliability must be achieved in spite of increased functional requirements, subsystem complexity and exposure to more severe induced operating environments. The F-22 Team's approach to designing reliability into subsystem hardware is called the F-22 Subsystem Integrity Program. The goals of the program are to increase reliability, campaign effectiveness and safety. These goals will be attained through a rigorous application of engineering principals including life analyses and realistic environmental testing. As part of the Subsystem Integrity Program, the F-22 Team sponsored industry wide supplier conferences to share design, analysis and test approaches and results. The purpose of this paper is to summarize the top level management and technical lessons learned in the implementation of the F-22's Subsystem Integrity Program. The two most important management lessons learned are (1) schedule-the disciplined implementation of the integrity program was key to keeping flight certification process on schedule and (2) cost-reliable subsystem components reduce initial acquisition costs (initial spares) as well as customer life cycle costs. A key technical lesson learned is that many Mil-Std tests are not adequate in severity or duration to achieve the cost and schedule benefits described.