MASTER'S THESIS Airplane Field Support Physical device for maintenance technicians Miriam de Tomás Álvarez 2014 Master of Science in Engineering Technology Industrial Design Engineering Luleå University of Technology Institutionen för ekonomi, teknik och samhälle Master/Bachelor of Science Thesis Airplane Field Support Maintenance Technician’s physical device Master/Bachelor of Science Thesis in Industrial Design Engineering- Product design and development © Miriam de Tomás Álvarez Published and distributed by Luleå University of Technology SE-971 87 Luleå, Sweden Telephone: + 46 (0) 920 49 00 00 Printed in Luleå Sweden by Luleå University of Technology Reproservice Luleå, 2014 Table of contents I. Introduction 1 IV. I. VII The Back Offices IV. I. VIII Whiteboards I. I Background IV. I. IX Logbook I. II Project objective and aims IV. I. X Pocket book I. III Deliverables IV. I, XI Problem solving I.III.I Sub Deliverables IV. II Interview I. IV Delimitations and limitations IV. III General conclusions I. V Military Base’s definitions IV. IV Most interesting observations II. Theory 6 V. Benchmarking 26 II. I Design Theory V. I The company II. II Accessibility V. II The market II. III Comparison V. II. I Definitions II. IV Freeze-Flight-Fight-Forfeit V. II. II Similar Products II. V Usability V. II. III Competition Analysis II. VI Satisficing V. III The user II. VII Virtual & Augmented Reality V. III . I User surveys II. VIII Ergonomics V. IV Other analysis V. IV. I Environmental III. Method 11 V. IV. II Ergonomics V. V Conclusions V. VI Problem identification III. I Competitor study III. II Field observations III. III Interviews VI. Requirements 35 III. IV Product Design Specification III. V Mood board VI. I Product Design Specification III. VI Brainstorming III. VII Wordle VII. Concept Development 38 III. VIII Prototyping III. IX Personas VII. I Idea Generating III. X Cyclic Process Design VII. I. I Moodboards III. XI Identifying user needs VII. I. II Brainstorming VII. I. III Wordle IV. The Present 16 VII. II Concepts VII. II. I First concept IV. I Field observations VII. II. II Second concept IV. I. I Division of the tasks VII. II. III Third concept IV. I. II Documentation VII. II. IV Fourth concept IV. I. III Systems used VII. III Concept Evaluation IV. I. IV Checks and repairs IV. I. V The Hangar IV. I. VI The Line Table of contents VIII. Further Development 45 Figures Figure 1. Different armed forces VIII. I Formal and Functional design Figure 2 -3 . Swedish Air Force. Wikipedia Figure 4 . Swedish Air Force. F21 Luleå VIII. I. I The 3d glasses Figure 5. Comparison. Chose the best way. VIII. I. II The earphones Figure 6. International standards for HCI and usability VIII. I. III The throat microphone Figure 7. Example of Wordle method VIII. I. IV The flexible tape Figure 8. The hangar at F21 VIII. II Formal aspect/ Analogies Figure 9. An example of the line Figure 10. Similar example of the whiteboard at F21 VIII. III Sizing of the product Figure 11. Example of the logbook used by the thech- VIII. IV Materials nicians. VIII. V Ergonomics Figure 12. Problem solving. Example in the Line VIII. VI Prototyping Figure 13. Symbols that represent possible problems VIII. VI. I Modelling detected during the visit to the F21. Figure 14. Saab’s core values. (Saabgroup Website) VIII. VI. II Rendering Figure 15. Saab 39 Gripen users worldmap VIII. VI. III Mock-up Figure 16. Sensory channels in the VR. Figure 17. Sequence of events analysis by XM Reality Figure 18. Augmented Reality BMW IX. Final Results 53 Figure 19. Moodboard related to the military field. Figure 20. Brainstorming IX. I Final Results Figure 21. Wordle related to military field. IX. II Interface Figure 22. Workshop to find new ideas. Figure 23. First concept Figure 24. Second concept X. Evaluation 58 Figure 25. Third concept Figure 26. Third concept X. I Discussion Figure 27. Third concept Figure 28. Fourth concept X. II Recommendations Figure 29. Sketches for the earphones’ development Figure 30. Bose QuietComfort 20. Doble function. XI. References 62 Figure 31. Sketches with several proposals of design Figure 32. Sketch of the chosen earphone Figure 33. Different cuff mechanisms XI. I Electronic Figure 34. Sketches with the final idea XI. II Books Figure 35-36. Analogies with the Jas 39 Gripen XI. III PDF Figure 37. Global measures of the device XI. IV Pictures Figure 38-39. Modelling in Alias Autodesk Figure 40. Rendering in Alias Autodesk Figure 41. Position the different pieces to print. XII. Appendix 64 Figure 42. Printed pieces in ABS Figure 43. Final mock-up. Figure 44. Final device. Appendix I - Environment analysis Figure 45. 3D glasses and the throat microphone. Appendix II - User analysis Figure 46. Technician using the final device. Appendix III - Ergonomic analysis Figure 47. Scheme of a possible interface Appendix IV - General Market Figure 48. Example of the home page Appendix V - Weighting Grid Figure 49. Personnel Identification. Example of inter- face. Figure 50. Personnel Identification. Example of inter- face. Figure 51-52. Problem Identification. Example of interface. Figure 53. Blueprint. Example of interface. I. INTRODUCTION I. Introduction The focus of this report is a master thesis pro- ject for a Master of Science examination in I.II Project objective Industrial Design engineering at the Luleå University of Technology, during the spring and aims semester of 2014. The objective has been to This project will focus on the various methods develop a physical device for the technicians of current maintenance. This study will be fo- of the Swedish Air Force. The objectives and cused primarily on this area, but it can also be aims of the project are presented in this chapter interesting to study other alternatives. The aim along with the project incentives, stakeholders is to identify problems and challenges, and with and scope. that as base develop possible solutions. This will require careful analysis of the work environ- ment, the user, the market, competition, etc. I.I Background In this way a device can be designed to pro- vide a better aircraft maintenance, by techni- Saab is a Swedish brand, that was shared by cians, reducing the need of paper handling. The two different companies, Saab Automobile AB purpose of this project is to facilitate airplane which manufactured cars, and Saab AB. Saab maintenance, and the goal is to develop a de- was founded 75 years ago with the mission to sign concept that optimizes usability and inte- secure the nation’s supply of military aircraft as raction between system and operator. part of our drive to maintain our national se- The main purpose of this project is to build curity and sovereignty. This company is divided a physical device that is to assist the field te- in different organizations: Aeronautics, Dyna- chnicians when servicing the JAS Gripen. It mics, Electronic Defense Systems, Support and consists of developing an existing technology Services, among others. and use it in a new way so that the technicians can work on the airplane while having access Although this company develops several ty- to all necessary documentation for the service pes of responsibilities and projects, one of its and repairs. For it, it will be necessary to take main objectives is the development, produc- into consideration several design aspects such as tion, marketing, selling, and supporting of its safety, ergonomics, users, quality, and usability. Gripen fighter. One of the goals is to design a product after having carried out a exhaustive study, in which, The maintenance of aircraft is carried out at several problems have been found, so in that the bases and it plays a really important role way try to improve and create something in- for Saab’s company. The main goal in this pro- novative and useful. ject is to design a product which facilitate the Human-Machine Interaction (HMI) in the context of maintenance. 1 I. Introduction I.III Deliverables 7. Further development of chosen concept, every detail should be worked thoroughly. For the appropriate development of this pro- ject, it is necessary to carry out a careful and 8. A final concept presented using 3D rende- thorough analysis. This project ‘s main objec- rings with possible of some recommendations tive is to design a device for the maintenance for manufacturing and further development of technicians who work with the aircraft ,and it. it is therefore important that the product will meet user’s high demands from a formal and functional point of view. To carry out this pro- ject, a great emphasis was put on understanding I.IV Delimitations the human satisfaction, both for mechanics, which are those that use the product , as for those dependent users of it ( such as drivers and limitations , passengers, among others). The final concept will use existing technology, or technologies The result will not consist of a complete solu- that are currently in development process. tion but a foundation for further development. - The time limit for the project is five months. I.III.I Sub Deliverables - No consideration will be taken concerning software solutions to the interface. 1. Understand the maintenance technicians’ tasks with the aircraft, as well as, the current - No consideration will be taken concerning market related to the high technologies. electric components. 2. Identify the wants and needs of the users. - No consideration will be taken concerning economy and costs. 3. Analyse the high tech market related to aug- mented reality and define the different seg- - The structural calculations are not included. ments that have been found, their strengths and Scale plans will be created to define the mea- weaknesses.