Extending CMMI to Hardware Engineering Disciplines

1. Extending CMMI to Hardware Engineering Disciplines NDIA System Engineering Conference October 2003 Scott Potter Harris Corporation Govt. Communications Systems Division Digital Technology and Network Systems Assured Communications

2. Introduction • Extending CMMI to Hardware Engineering Disciplines • Application context • Process improvement infrastructure • Hardware process improvement objectives • Improvement approach • Metrics • Lessons Learned • Summary Assured Communications

3. Hardware Application Context Assured Communications

4. Engineering Process Improvement Engineering VP, Program Area VPs, EIT Director • Executive Steering Group • Coordinate and Manage • Cross-disciplinary Action Teams • Systems Engineering • Software Engineering • Electrical Engineering • Mechanical Engineering • Antennas / RF / Optics • Integration & Test Engineering • Specialty / Support Engineering • Engineering Information Technology Engineering Process Council (EPC) EPG Leader, EPG Staff, Discipline Leads Engineering Process Group (EPG) Engineering Managers, Staff Discipline Teams (8) Action Teams Tools, Methods, and Technology (TMTs) Short-Term Tasks Long-Term, Persistent Assured Communications

5. Continuous Process Improvement 2 Managed CMMI Process Areas Staged Maturity Level Focus Process Areas (PAs) Quality Productivity Organizational Innovation and Deployment Causal Analysis and Resolution 5 Optimizing Quantitative Management Organizational Process Performance Quantitative Project Management 4 Quantitatively Managed Requirements Development Technical Solution Product Integration Verification Validation Organizational Process Focus Organizational Process Definition Organizational Training Integrated Project Management Risk Management Decision Analysis and Resolution 3 Defined Process Standardization Requirements Management Project Planning Project Monitoring and Control Supplier Agreement Management Measurement and Analysis Process and Product Quality Assurance Configuration Management Basic Project Management Risk Rework 1 Initial Assured Communications

6. Completed In-Progress Pending Hardware CMMI Action Plan HW Command Media HW Metrics Deployment HW CMMI Mini-Assessment Process Updates • Action teams • Command media • Command media gaps • Judge institutionalization • Integrated metrics tool • (SE, SW, HW) • Baseline (pre-CMMI) • Integrated EPG CCB HW CMMI Mini-Assessment Process and Training Updates • Command media • Training updates • CMMI delta training • Delta mini-assessment Deploy HW CMMI Process Updates, Training, and Institutionalization … Project SE/SW/HW CMMI Mini-Assessments, QA audits … SE/SW Process Deployment, Training, Assessments, and Improvement Assured Communications

7. Engineering Development Process Division Standard Engineering Process • Policies Project Defined Processes • Manuals • SEMP • SDP • EDP • MDP • Other plans • Handbooks (inter-disciplinary processes) • Training (process and technical) Assured Communications

8. Electrical Engineering Process Overview • EE manual – process flow diagram • Integrated command media across all engineering disciplines • Standard life cycle phases • Activities, products, milestones, baselines • Sub-process / Interfaces with SE • Checklists and design/peer reviews based on SE-based process Assured Communications

9. Hardware Improvement Objectives • Competitive bids • Productivity metrics • Labor metrics • Predictive metrics • Predictable performance vs. plan • Technological Capabilities • State of the art technology • Innovative project applications • Attract and retain creative talent These objectives drive how we plan and manage Assured Communications

10. Hardware Improvement Projects • HW Tools, Methodology, and Technology (TMT) initiatives • Special projects (lessons learned) • Standardization of work products • Design archive (cost history) • Metrics database • Benchmarking; tool evaluations; process reviews • Technology roadmaps; • Digital Engineering Technology areas (TMTs): • ASIC/FPGA (advance semiconductors) • Microsystems (microelectronics, MEMs, optics) • Network systems • Signal processing • Metrics • Productivity • Qualitative information on designs (e.g. PWB metrics) • Circuit card archive Assured Communications

11. Hardware Metrics • Metrics are collected, analyzed, and used to track project hardware engineering progress, performance, and quality • Process characterization • Predictive metrics • Historical performance • Productivity • Cycle time • Technical performance (capability, TPMs) • Timing, sizing, link budgets, etc. • Emphasis varies by program and application • Engineering Cost Metrics Database (timecard charges) Assured Communications

12. Hardware Historical Metrics Circuit Card Archive • Database of circuit cards • By program • Card count and description • Design summary / structure • Links to existing cards, SEER-H • Defines work codes for metrics • Reuse characteristics SEER-H Estimating model and metrics • Status • Metrics • Progress Management PWB Database ASIC/FPGA Database Fabricator • Design status • Fabrication status • Approved vendors • Standard forms, templates • Used to track supply chain. Buyer, designer, QA, fabricator, and purchasing to electronically share, communicate, and track status Assured Communications

13. Define the Scope of Work Create A Bottom-Up Estimate Establish The Requirements Requirements BOE Forms Document • Block Diagram • Material List • Travel, ODC • Subcontracts • Capital & Facilities • Design Process Map Conceptual WBS & Program Schedule Design Requirements Review Qualify The Bottom-Up Estimate • Compare against • similar-to design • productivity metric • parametric tool as appropriate • Metrics • Design Archive • Program Cost History Proposal Cost Review NO Design To Cost met? YES Complete The BOE Form and Generate the Proposal Cost Review Summary Review Forms With Engineering Manager (Include costs from financial administrator) Proposal Cost Review Summary H-2472 BOE Create a bid for each WBS element Forms Proposal Cost Review Summary Form(s) Hardware Estimating Process Assured Communications

14. Electrical Engineering Performance Proprietary Information – For Internal Division Use Only <ExampleProject> Reporting Period: September 1999 PEM v3.0 Electrical Engineering Pins Issues/Actions Electrical Engineering Gates Issues/Actions "Pins" issues/actions "Gates" issues/actions Assured Communications

15. Trending - PWB Cycle Time Average Calendar Weeks Per PWB Assured Communications

16. Trending - PWB Quality Percent Of PWBs Error-Free Assured Communications

17. Trending - PWB Defects Per Design Number of ECOs and SIRs Per Design Assured Communications

18. Training • Customized employee training based on assigned role and gap analysis • All PCB designers are IPC-certified • Process training (design of circuit cards, FPGAs, MCMs, PWBs) • Web-based tutorial • New hire orientation Assured Communications

19. Quality Assurance • Process compliance and product quality is assured by Engineering Management oversight and quality audits • Periodic audits of PWB vendors • Supplier summits • Defect metrics • Change requests Assured Communications

20. Lessons Learned • Start a CMMI improvement project with a baseline assessment • Understand the model • Identify gaps • Implement the actions • Ensure representation across projects and disciplines • Metrics help define, characterize, and improve processes • Identify the prioritized areas for improvement • Start small, look for value • Use available data first before creating something new Assured Communications

21. Contact Information Scott Potter Harris Corporation GCSD Digital Technology & Network Systems spotter@harris.com 321-729-7863 Harris Corporation Govt. Communications Systems Division P.O. Box 37 Melbourne, Florida 32902-0037 http://www.harris.com/ Assured Communications