Rapid Prototyping - Booz Allen Hamilton

Rapid Prototyping
The Agile Creation of Solutions for Modern Defense & Intelligence
by
Lee Wilbur
wilbur_lee@bah.com
Allan Steinhardt
steinhardt_allan@bah.com
Rapid Prototyping
The Agile Creation of Solutions for Modern Defense & Intelligence
Executive Summary
For federal military and intelligence agencies, traditional
rapid prototyping has filled a minor role in the engineering
and production of solutions for users and operators. The
old purpose was “embedded functionality now, form and fit
later”—basically, to create hardware or software with scaled
functionality. The traditional prototype had no physical constraints of size and interoperability required for the fielded
system, so it allowed users to test functionality at reduced
cost. Traditional prototypes also helped in testing an
emerging technology or served as a step for risk reduction
in a major development program. In this Viewpoint, we propose a redefinition for federal agencies: Rapid Prototyping
is an agile system, putting solutions for warfighting and
intelligence quickly into the hands of users and operators,
providing a good portion of needed capabilities upfront in
the short term, and gradually upgrading functionality that
is based upon continuous input from the field. The integration of standard off-the-shelf commercial technology often
makes form fit a minor step in the process of creating vital
solutions.
Booz Allen Hamilton's definition of Rapid Prototyping
is a sharp change from traditional major development
programs, which are historically inflexible, have long
timelines and are expensive. Unlike the traditional model,
Rapid Prototyping will allow federal users and operators to
quickly and cost-effectively obtain vital solutions to fulfill
urgent missions. The new role for Rapid Prototyping meets
a crucial requirement as the federal government must now
rapidly respond to unpredictable emerging threats such
as irregular warfare and international crime within the
constraints of reduced fiscal resources.
New Environment for Defense & Intelligence
Federal procurement programs are largely designed
and implemented around outmoded defense and
intelligence missions. Those missions usually were
based on predictable actors and threats. Examples
are deploying the military against threats by specific
nation states or when conflicts are defined by specific
military theatres.
In these contexts, the federal procurement process
had the luxury of time to develop detailed specifications that theoretically covered all requirements. In
turn, contractors developed major programs to customize design and manufacture solutions. Iconic examples
are military aircraft, vessels, and ground vehicles.
These require huge upfront investments. Development
is complex because equipment like this can rarely
tap benefits of the commercial world, which has no
counterpart. Major programs also require supply chain
management, training, and ongoing support on the
back end. The result is a massive, complex, inflexible
system that is fraught with cost overruns and often
results in an endless life of its own. Costs to operate
and maintain major programs run higher when the
original equipment manufacturer owns the design and
intellectual property. By default, there is no opportunity for a competitive environment. With all this, it can
take years before warfighters or operators can use the
equipment—whether or not it effectively meets the
requirements of an agency’s mission.
There is a new reality governing priorities for 21st century defense and intelligence. Nation states can still
pose threats, but many of the most urgent threats now
come from non-national sources—including independent terrorist organizations and individuals capable of
executing acts of mass destruction. Military agencies
are also responding to more than irregular warfare, as
law enforcement and intelligence increasingly requires
help with incidents of coordinated international crime.
These threats include illicit trafficking of narcotics, illegal mining, human slavery, counterfeit goods, money
laundering, and theft of intellectual property. The new
threats change constantly, and so do their players.
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These asymmetric threats may also come from a combination of rogue nations, terrorists, and criminals.
Traditional solutions and their procurement process
cannot meet the rapidly evolving threats of the 21st
century. To meet these challenges with agility, federal
agencies need a development, manufacturing, procurement, and support process that enables flexibility and
more responsiveness. We believe Rapid Prototyping is
the strategic solution for this challenge.
History of Rapid Prototyping
1. Digital Hardware
Prototyping
Started in late 1970s using field programmable gate arrays to quickly prototype a digital
chip without full design and implementation. By solving “just enough” of the design
goals, gate arrays often became the functional solution.
2. Software
Prototyping
Since the 1980s, high level graphical programming languages allowed prototyping of
software without writing code. Many of the results worked well enough to have routinely
become the systems they were meant to emulate.
3. Manufacturing
Rapid Prototyping
Since the 1990s but still in its infancy, this phase enables 3D printing or “constructive
assembly” where a computer controls the building of a macro-scale end product from raw
materials. Results are mostly to form fit design before functional production. Where there
is functionality, machine assembly time is too slow for volume production.
4. Rapid Prototyping
for the Warfighter
Defense and intelligence agencies can now obtain functional solutions faster by using
rapidly engineered and produced field prototypes with standard, off-the-shelf components. This enables results in weeks or months, not years, and addresses constantly
changing mission needs.
A Better, Agile Way to Make Solutions
for C4ISR
Many solutions for defense and intelligence are
often lumped under the “C4ISR” moniker: Command,
Control, Communications, Computers, Intelligence,
Surveillance, and Reconnaissance. Contractors have
targeted C4ISR solutions at this umbrella since the
architecture and framework was established in 1996.
Government procurement usually begins by stressing
definition of complex requirements, so the response
of contractors results in systems development cycles
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of five, eight, even 12 or more years long. One
example is a stealthy super maneuverable fighter
aircraft called the F-22 Raptor. Development began
in 1981; it became operational in 2011. During its
30-year gestation, the F-22 was plagued with faulty
subsystems and frequent groundings. Adversaries
are adapting faster than this so the old model is
inadequate. Federal agencies need a better, more
agile way to make solutions for unpredictable C4ISR
mission needs.
To break this pattern, we recommend a shift in
defining priorities for C4ISR solutions. The Achilles
heel is a traditional penchant for defining every
conceivable requirement that might apply to a
particular solution throughout its projected lifecycle.
Frankly, it is impossible to achieve this goal because
requirements to thwart asymmetric threats are
continuously evolving. The legacy procurement process
therefore sets up users and operators for frustration
and impedes mission accomplishment. The new
priority should be quickly producing solutions that
are “good enough” in providing most mission needs
now. Waiting for a perfect solution takes too long and
may well not meet the mission need once it becomes
available.
This is the essence of Rapid Prototyping. Our concept
of Rapid Prototyping produces functional solutions
that can be quickly fielded by considering form
factor up front. For example, Booz Allen developed,
tested, perfected and deployed a new airborne
measurement and signature intelligence capability
in direct operations within 18 months for a federal
client. In another case, a military command asked
us to develop a new targeting capability. After a few
weeks of laboratory work, we demonstrated sufficient
performance with simulated data to be invited to an
operational exercise. We expect the system to deploy
within four months of successful demonstration.
During the Rapid Prototyping process, people in the
field can provide real-world feedback, which we can
use to quickly modify and upgrade the solution in
response to actual new threats. This is an efficient,
adaptable, and interactive lifecycle that accomplishes
major goals of the mission.
C4ISR integration is a primary area where Rapid
Prototyping will benefit federal agencies. One of the
most urgent requirements for defense and intelligence
agencies is identifying and tracking emerging
threats. C4ISR integration entails combining sensors,
radios, and networks on platforms that support new
and different missions. We pioneered the use of
GoogleTM Earth to fuse pictures, videos, text, and
other information into a new functional interface. To
illustrate a C4ISR integration, Booz Allen used the
Microsoft Kinect for Windows software development
kit to, within a week, develop a program that provides
3D mapping prototypes of urban terrain for ground
forces. This scenario rapidly leveraged developments
in the commercial world for a functional military
application—a textbook example of Rapid Prototyping.
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Rapid Prototyping also meets challenging fiscal
goals as federal budgets tighten funding for defense
and intelligence agencies. A key cost-saving aspect
of Rapid Prototyping is in the avoidance of original
engineering. Whenever possible, solutions developed
with Rapid Prototyping use existing, off-the-shelf
components that are integrated in a new and different
way to achieve intended functionality. In this manner,
Rapid Prototyping helps to avoid the obsolescence
of traditional systems and, by incorporating field
responses with incremental improvements, it can
Case Study: 3D Mapping
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Problem
Terrestrial mapping solutions for the
Department of Defense were inadequate
for urban terrain, transportability was
poor and they were expensive
Solution
To illustrate a C4ISR integration, Booz
Allen used the Microsoft Kinect for
Windows software development kit to,
within a week, develop a program that
provides 3D mapping prototypes of
urban terrain for ground forces
Result
The Rapid Prototype mapping system
costs about $100 but performs in the
ballpark of a traditional half-milliondollar military system
cost-effectively leverage the technology innovations
by commercial developers. The mapping system
described above costs about $100 but performs
in the ballpark of a traditional half-million-dollar
military system.
Injecting adaptability into C4ISR systems is another
benefit of Rapid Prototyping. A major drawback of
managing traditional systems is the uncertainty in
knowing what the next conflict will be like and where
it will occur. It’s a dual challenge of whether old
solutions will have the right response capabilities
and if they will be deployable in a different global
region. For example, it’s virtually certain that some
solutions developed for the arid, desert environments
of Iraq and Afghanistan will be unable to operate in a
tropical environment with high humidity, salt water and
the absence of roads for transporting the solutions.
To address adaptability, Booz Allen has used Rapid
Prototyping to develop radar systems for foliage and
ground penetration for numerous federal agencies. In
a military test, we will soon demonstrate an integration
that fits on a small tactical Shadow UAV. The project
began in January 2012; it will fly on a manned
system in May 2012 and could be deployed this year.
This is how Rapid Prototyping can quickly surmount
unpredictable challenges and adapt solutions to new
threats wherever they occur.
Challenges for Adopting a Rapid
Prototyping Strategy
Switching from the old development model to Rapid
Prototyping entails several challenges. Foremost is
a strong push for agencies to accept the idea of getting 60 to 80 percent of desired functionality upfront
(albeit much quicker), and setting expectations for
gradual upgrades over time. We’ve noted the benefits
above. It’s also important to plan for system ramifications as these will be significant.
For example, the procurement process would require
Requests for Information (RFIs) and Requests for
Proposals (RFPs) to focus more on mission themes
and timelines instead of presenting a detailed
multitude of specifications for every possible feature.
This occurs frequently with Joint Urgent Operational
Needs, which grants the military rapid acquisition
authority to eliminate a capability deficiency that
has resulted in combat fatalities. Booz Allen has
used mission theme-oriented procurements for
Rapid Prototypes of C4ISR for several Defense
agencies. Each took just a few months including lease
procurement, network installation, classified computer
access, data center build out and fusion software
integration. In these cases, the prototypes functionally
blended into operational use. By prioritizing themes
and timelines, contractors will be able to get the
essence of a solution quickly into the hands of users
and operators and schedule less important features
into later iterations of the product. Obviously users
and operators will fulfill a critical role in procurement
by advising acquisitions specialists on how to frame
descriptions of features and timing for RFIs and RFPs.
Other areas ripe for modernization include training,
maintenance, and support for solutions provided with
Rapid Prototyping. Existing systems for these areas
focus almost exclusively on traditional major development programs. As defense and intelligence agencies
shift to Rapid Prototyping to stay agile against emerging threats, the back end of sustainment, logistics,
and training will also need realignment with new solutions that quickly appear in the hands of
Case Study: Wolfhound Sensor
Problem
Quickly fielding man-portable electronic
gear to locate enemy electronic emmitters
Solution
Booz Allen adopted commercial programmable hardware and software to quickly
field an effective solution
Result
The Wolfhound Sensor saved lives of war
fighters
users and operators, and are upgraded on a faster
and continuous basis. An example is training users
in the use of techniques with counter improvised
explosive devices. Training is mandatory—both
in use of the technology and preparing operators
to enhance its use with local indigenous culture.
Booz Allen has built and deployed Rapid Prototype
training modules for dozens of clients, each in just
a few weeks. Training programs will need to tap the
efficiencies of virtual, network-based curricula to help
warfighters keep apace of new technologies. Likewise,
organizations responsible for logistics support will
need to leverage the commercial supply chain as
those technologies are integrated with solutions
produced with Rapid Prototyping. By tapping the
commercial supply chain, military and defense logistics
will find sourcing parts availability to be more reliable
and cost efficient—especially when they do not need
to produce these from scratch.
Leveraging Booz Allen Hamilton for Rapid
Prototyping
As federal agencies consider capturing the benefits of
Rapid Prototyping, Booz Allen is uniquely positioned to
help smooth the transition. Our company has a long
relationship with federal agencies, which brings deep
insight of individual missions to the Rapid Prototyping
process. As a result, we can more effectively
tailor Rapid Prototyping solutions to meet mission
requirements.
Booz Allen engineers interact with an agency’s
users and operators to help them identify solutions
that will quickly address unique, emerging threats.
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needs to competitively procure standard commercial
parts for each new solution. As a result, agencies
are able to mass produce the best quality tool at the
best price. We do this for enhancements of armor and
communications of ground vehicles, with turnaround
times measured in months, not years.
Another benefit for federal agencies using Booz
Allen’s services for Rapid Prototyping is that the
government owns the resulting design and intellectual
property (IP). This is different from original equipment
manufacturers that often retain ownership of the
IP, which locks agencies into the same supplier for
future iterations of solutions based on the underlying
technology or design. Booz Allen is truly independent,
so we are not tied to a specific platform, technology,
or vendor—allowing us to offer solutions that are
unencumbered and integrated to provide the best
functionality. In each case, we provide all intellectual
property to the government. For example, our
GoogleTM Earth-compliant data packages (called
KMZ files), are widely shared across government
networks. Pioneering leadership by Booz Allen in
openly sharing intelligence products has spawned a
“viral” online community of users across government
and contractor communities, each contributing and
building data layers. In cases where an agency might
want to adapt existing proprietary solutions, Booz
Allen can reverse engineer mechanical and electrical
designs and give the government all the information it
Conclusions
In summary, Rapid Prototyping is the new strategic
way for federal defense and intelligence agencies
to stay agile in their response to emerging threats,
by quickly getting effective solutions into the hands
of warfighters and operators. By making Rapid
Prototyping a core strategy for national security,
federal agencies will be able to better protect citizens
from emerging threats wherever they appear, and to
accomplish this critical mission while meeting new
fiscal requirements.
CONCEPT
• User Req’ts
• System Req’ts
• CONOPS
development
• PDR
DESIGN
• Technology scouting
• Modeling/simulation
• Specifications
development
• CDR
DEVELO
P/
M
Booz Allen Rapid Prototyping Process
IFY
OD
IN
ATE
GR
TE
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Our experience allows us to closely participate in
the design and integration process, which helps
the resulting solution to be relevant and effective.
Booz Allen also has a unique screening process
for evaluating candidate technologies for a Rapid
Prototyping solution.
TEST
• Hardware build/prototyping
• System integration
• Developmental testing
EVALUATE
• Field testing
• Utility assessment
• Demonstration
DEPLOY
• Flight operations
• Sensor operation
• PED
• OCONUS
deployment
Our Rapid Protoyping process is a streamlined version of the traditional systems engineering “V”
Case Study: Hindsight Sensor
Problem
Provide convoys in war zones with the
ability to detect improvised explosive
devices (IEDs) during vehicle transit
Solution
Booz Allen equipped small unmanned
aircraft deployable from a land vehicle
with sensors that can detect small
changes on the ground indicating buried
explosives and other related activity
Result
First ever real time high resolution synthetic aperture change detection sensor
on a standard issue tactical military
unmanned aircraft
Booz Allen Engineering Services
Rapid Prototyping
Creates functional defense and intelligence solutions faster by rapidly engineering and producing field prototypes to meet any request in weeks or months,
not years. Addresses constantly changing, unanticipated mission requirements
with unique engineering design solutions using standard off-the-shelf components and technology.
System Engineering &
Integration
Applies tailored system engineering and integration principles to a wide range
of systems, reducing cost and delivering increased capabilities within the
desired schedule. Includes Enterprise Integration, Engineering and Science,
Systems Engineering and Integration, Acquisition and Program Management,
and Supply Chains and Logistics.
Energy
Proven approach to complex energy engineering projects delivers demonstrable, sustainable energy solutions that achieve ROI and meet the mission need.
Provides answers for Department of Defense’s complex energy supply chain
and logistics problems with speed, precision and certainty.
Applied Sciences
Exploits science for viable technical solutions, leveraging diverse technical disciplines and the firm’s resources to address client missions. We provide broad,
deep technical knowledge and highly specialized expertise in physics, materials
and biology.
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About the Authors
Lee Wilbur is a senior vice president at Booz Allen
Hamilton where he brings more than 25 years of
executive management, program management, and
systems engineering experience with missile defense,
space, aircraft, and ground combat systems.
His background includes extensive experience in
complex system development and supporting system
engineering technologies.
Dr. Allan Steinhardt is a vice president at Booz Allen
Hamilton where he provides engineering services to
the Office of the Secretary of Defense. Steinhardt is
a Fellow of the IEEE, has published over 100 articles
in academic and defense strategy journals and a
radar textbook. His background includes program
manager and chief scientist for DARPA, National Labs
scientist, and professor at Cornell University.
Contact Information:
Lee Wilbur
wilbur_lee@bah.com
Senior Vice President
703-377-7321
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Allan Steinhardt
steinhardt_allan@bah.com
Vice President
703-984-3850
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