Rapid Prototyping. The Agile Creation of Solutions for Modern Defense & Intelligence. by Lee Wilbur wilbur_lee@bah.com

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1 Rapid Prototyping The Agile Creation of Solutions for Modern Defense & Intelligence by Lee Wilbur Allan Steinhardt

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3 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. 1

4 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. 1. Digital Hardware Prototyping 2. Software Prototyping 3. Manufacturing Rapid Prototyping 4. Rapid Prototyping for the Warfighter History of Rapid 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. 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. 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. 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 Government procurement usually begins by stressing definition of complex requirements, so the response of contractors results in systems development cycles 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 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. 2

5 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. 3

6 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 Problem Solution Result Case Study: 3D Mapping Terrestrial mapping solutions for the Department of Defense were inadequate for urban terrain, transportability was poor and they were expensive 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 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. 4

7 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 Problem Solution Result Case Study: Wolfhound Sensor Quickly fielding man-portable electronic gear to locate enemy electronic emmitters Booz Allen adopted commercial programmable hardware and software to quickly field an effective solution 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. 5

8 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. 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 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. 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. User Req ts System Req ts CONOPS development PDR Booz Allen Rapid Prototyping Process CONCEPT DESIGN EVALUATE DEPLOY Technology scouting Modeling/simulation Specifications development CDR DEVELOP/MODIFY TEST Hardware build/prototyping System integration Developmental testing Field testing Utility assessment Demonstration Flight operations Sensor operation PED OCONUS deployment Our Rapid Protoyping process is a streamlined version of the traditional systems engineering V INTEGRATE 6

9 Problem Solution Case Study: Hindsight Sensor Provide convoys in war zones with the ability to detect improvised explosive devices (IEDs) during vehicle transit 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 Applied Sciences 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. 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. 7

10 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 Allan Steinhardt steinhardt_allan@bah.com Vice President

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