T2-3: Engineering process

1. T2-3: Engineering process Chin-Sheng Chen Florida International University

2. T2-3: Engineering process • Engineering process • Need and specification • Modeling and analysis • Functional design • Implementation design

3. The ESE Framework –Re-visit

4. Readings & References • Readings: • HEA: Chapter 2 • Reference • Product design and development by Karl Ulrich and S. Eppinger, McGraw-Hill, 2002

5. Engineering process – need and specification (1) • Need, definition • An attribute of a potential system (product) that is desired by the customer. • Other names: customer attributes, customer requirements • Guideline for need statements • Express the need in terms of what the system (product) has to do, not how. • Express the need as specific as possible • Use positive, not negative phrasing • Express the need as an attribute of the system (product). • Avoid using the words must and should. • Organize needs into a hierarchy • Establish their relative importance

6. Engineering process – need and specification (2) • Specification, definition • A precise description of what the system (product) has to do. • A specification has a metric and a value. A value may take on several forms such as a number or a range. • A specifications is a set of the individual specifications. • Other terms used: • system (product) requirements, engineering characteristics, technical specifications

7. Engineering process – need and specification (3) • Specification types: • Target specifications: • Preliminary, ideal specifications • Final specifications (in the contract book) • Final specifications depend on • what customers needs, • what is technical and economic feasible and • what our competitors offer in the market place.

8. Engineering process – need and specification (4) • Metrics • The most useful metrics are those that reflect as directly as possible the degree to which the system (product) satisfies the customer need. • Metrics must be precise and measurable such that meeting specifications lead to satisfaction of the related customer needs • A need may be translated into more than one metrics, and one metrics may satisfy one or multiple needs.

9. Engineering process – need and specification (5) • Setting metrics value • Competitive benchmarking • Set ideal and marginally acceptable target • Develop technical and economic models to assess feasibility • Use the above data to create competitive maps and conduct trade-off analysis

10. Engineering process – need and specification (6) • Hierarchy of system specifications • Each system (product) may have a hierarchy of subsystems (products). • Each subsystem has its specifications • Therefore, the overall specifications for the system must be decomposed (or flowed down) to hierarchical sets of specifications, one for each subsystem.

11. Engineering process – modeling and analysis (1) • Model, definition • Analytical or physical approximation of the system (product), used as a tool for predicting the values of the metrics for a particular set of design decisions • Models can be focused or comprehensive, depending on the degree to which they implement all of the attributes of the system (product). • Various models (including prototypes) may be developed to support the engineering process including system specification, engineering analysis, functional design, and implementation design. • Modeling: • the process for creating a model that reflects a desired system representation for understanding, assessment, and/or communication. • Two well-known models: AS-IS and TO-BE.

12. Engineering process – modeling and analysis (2) • Analysis, Def. • An engineering activity that uses a mathematical means or an engineering tool (such as a system or its model) to • understand and assess its behaviors and • Determine its desired end and the most efficient method of obtaining this (that is, to seek an optimal technical solution) • It may be exercised in all engineering phases. • Engineering analysis types: • A technical decision for • A specification • A system (product) solution approach • A functional design • An implementation design

13. Engineering process – modeling and analysis (3) • Engineering analysis • ESE focus • The system level of engineering analysis • The ESE analysis activity at system level • Input: • System (product) specifications • Output: • A technical solution approach • A conceptual design, for example

14. Engineering process – modeling and analysis (4) • Example of engineering analysis I • A die design: • Analysis issue: whether to use a progressive die or engineering dies. • Technical solution approach: use a sequence of engineering dies • Output: the WIP shape and size specification for each engineering die and its QA guidelines. • Example of engineering analysis II • An enterprise system design • Analysis issue: whether to use client-server or web-based system • Solution: use a hybrid approach of client-server and web-based. • Output: Interface and response time specifications.

15. Engineering process – functional design (1) • Functional design, def. • An activity that translates a conceptual design into an engineered system (product) design which meets the functional requirements as specified. • It should include industrial design, such as • use interface design and usability • Security and safety design • Functional design types • Architectural design • System architecture • Subsystems architecture • Components design

16. Engineering process – functional design (2) • Architecture, Def • A drawing (or structure) of something • A representation of all the processes involved in the life cycle of the something. • System architecture, Def. • A scheme by which the functional elements of the system are arranged into physical blocks and by which the blocks interact.

17. Engineering process – functional design (3) • Architectural design output (product) • Geometric layout • Assembly model • Bill of Materials (BOM) • Relationships • Fundamental interactions • Incidental interactions • Flow designs: • Coolant flows, • Mechanical & electrical flows • Material channels (runways)

18. Engineering process – functional design (4) • Architectural design output (physical system) • Geometric layout • Plant layout • List of plant components • Relationship • Fundamental interactions • Incidental interactions • Flow designs: • Aisles, staircases, driveways, conveyers

19. Engineering process – functional design (5) • Architectural design output (Computer/ Management Systems) • Layout design • Menu layout (organization chart) • Listing of menu items (components) • Relationship design • Flow design • information and work flows • Business processes • Communication channels

20. Engineering process – functional design (6) • Components design • For product • Competency and specifications • 2D/3D part drawings • For physical system • Competency and specifications • 2D/3D component drawings • For managerial system • Competency and specifications • functional procedures and diagrams, flowcharts, formulas, report, etc. • For computer system • Competency and specifications • Detailed object models, dynamic models, • functional procedures and diagrams, flowcharts, formulas, report, etc.

21. Engineering process – functional design (7) The three system layers - revisit • Physical system • Management system • Computer management system

22. Engineering process – implementation design (1) • Implementation design • Implementation approach • System-wide implementation plan • Detailed implementation plan • Deployment design • Deployment approach • (Process modeling and analysis) • Installation process design • Training design • Data migration design • Validation design • Switch-over design

23. Engineering process – implementation design (2) • For product design • Technical solution approach • Manufacturing technology • For example, material deformation (casting, molding, die-forming, crystal growing, etc.), removal (machining), or joining (welding) • System-wide implementation plan • Assembly process plans • Component implementation plan • Component process plans

24. Engineering process – implementation design (3) • For physical system design • Technical solution approach • Implementation technology • For example, use modular or integrated approach • System-wide implementation plan • High-level project action plan • Component implementation plan • Component process plans

25. Engineering process – implementation design (4) • For managerial systems design • Technical solution approach • Implementation technology • For example, use modular or integrated approach • System-wide implementation plan • System-level implementation plan • Component implementation plan • Component implementation plan

26. Engineering process – implementation design (5) • For computer system design (1) • Technical solution approach • Implementation environment & tools • For coding: C++ vs. Java • For structure: 3-layer vs. integrated

27. Engineering process – implementation design (6) • For computer system design (3) • System-wide implementation plan • Project management • Change management and version control • Packaging and installation process • System implementation plan • Guidelines for code structure, user interface design and documentation • Library of system standard components • Testing • Test policy and guidelines • Classes of tests • Expected software responses • Performance bounds • Identification of critical components • System debugging • Policy and strategy

28. Engineering process – implementation design (7) • For computer system design (3) • Component implementation plan • Flow implementation design • Program interface, flowchart, variables, parameters. • User interface implementation design • Interface details, messages design, on-line help & search • Form design • Data design (internal, global and temporary data structure in implementation, & variable conventions) • Software interface • Machine interface and system interface • Database implementation design • Table list, definition, and relationship

29. Engineering process – implementation design (8) • Deployment design (1) • Deployment approach • Unit by unit, or function by function • Top down or bottom up • Installation (upgrade) process design • Automatic or manual • Training process design • Development of use cases • Training programming • by unit or by function • Top down or bottom up • Online training

30. Engineering process – implementation design (9) • Deployment design (2) • Data migration/entry process design • Automatic or manual entry • Validation process design • by phase or one time • Switch-over process design • Gradual or one time

31. Engineering process – with focus onmethods and techniques (1) • ESE is different from other enterprise system-related efforts in its emphasis for development and application of methods and techniques to each engineering activity. They are: • Specification methods and techniques • Modeling and analysis methods and techniques • Design and optimization methods and techniques • Implementation planning methods and techniques

32. Engineering process – activity methods and techniques (2) • Enterprise strategy engineering process • Create (specify) strategic identity • Conduct strategic analysis • Formulate (design) strategy • Develop strategy implementation plan

33. Engineering process – activity methods and techniques (3) • Enterprise strategy engineering process (1) • Create the strategic identity • Define a mission • Develop a vision • Declare strategic intent • Identify core work (product/service)

34. Engineering process – activity methods and techniques (4) • Enterprise strategy engineering process (2) • Conduct strategic analysis • Develop an industry foresight • Identify current market, product/service and resource concepts • (Identify required new competencies)

35. Engineering process – activity methods and techniques (5) • Enterprise strategy engineering process (3) • Design (formulate) strategy • (Develop a balanced portfolio of capabilities) • (Develop a resource and capability acquisition agenda) • Strategically position the company • Create generic product strategies • Develop generic market strategies

36. Engineering process – activity methods and techniques (6) • Enterprise strategy engineering process • Design (formulate) strategy (3-1) • Strategically position the company (as a prospector, analyzer, defender or reactor), according to: • Org. readiness for risk taking • Readiness for developing new products • Technological orientation • Administrative orientation (type of company control)

37. Engineering process – activity methods and techniques (7) • Enterprise strategy engineering process • Design (formulate) strategy (3-2) • Create generic product strategies • Low cost or price differentiation • Image differentiation (distinctive design) • Support differentiation (after-sales service) • Quality differentiation • Design differentiation (added, improved production functionality) • Penetration strategy • Bundling strategy • Market, product and diversification strategies

38. Engineering process – activity methods and techniques (8) • Enterprise strategy engineering process • Design (formulate) strategy (3-3) • Develop generic market strategies • Size and diversity • Location (local, regional, national, global) • Stage of evolution • Emerging market • Established market • Eroding market • Erupting market

39. Engineering process – activity methods and techniques (9) • Enterprise strategy engineering process • Develop strategy implementation plan (4-1) • Plan to articulate and codify strategy, by translating it into • Strategic vision • Strategic objectives • Key success factors • (Key performance indicators) • (Key personal performance indicators) • Plan to evaluate strategy • For consistency, consonance, advantages, and feasibility

40. Engineering process – activity methods and techniques (10) • Enterprise strategy engineering process • Develop strategy implementation plan (4-2) • Plan to elaborate strategy • Transform the strategy into executable and operational plans in strategic and annual plans • Plan to promote strategy • To be advertised, debated, understood, and accepted by all employees • Plan to execute strategy • For launch of projects to implement the strategy • For carry-out of projects via execution actions, monitoring, and control • For evaluation of project success and strategy performance

41. Engineering process – activity methods and techniques (11) • Enterprise competency engineering process • Specify enterprise’s competency gaps, based on vision and strategy plans for product/service • Identify required new competencies • Conduct analysis for a technical approach to bridging the time-phased competency gaps • Identify a solution approach such as buying (licensing or outsourcing), cultivating, and/or co-developing. • Design a competency acquisition map • Develop a balanced portfolio of capabilities • Create a resource and capability acquisition agenda • Develop an implementation plan for securing required competencies • Develop a hiring & training plan for in-house resource acquisition • Develop a competency qualification plan for external resource acquisition

42. Engineering process – activity methods and techniques (12) • Enterprise capacity engineering process • Specify enterprise’s capacity gaps, based on vision, strategy, and competency. • Identify required new capacity • Conduct analysis for a technical approach to bridging the time-phased capacity gaps • Identify a solution approach such as buying (licensing or outsourcing), or cultivating a resource (a machine, a worker, or a computer system including an ERP system) • Design a capacity acquisition/decommission map • Develop a balanced portfolio of capacity requirement • Create a resource acquisition/decommission agenda • Develop an implementation plan for meeting time-phased capacity requirement • Develop a hiring & training plan for in-house human resource • Develop an acquisition plan for qualified external resources • Develop decommission plan for excessive resources

43. Engineering process – activity methods and techniques (13) • Enterprise structure engineering process • Define enterprise system structural specifications, based on vision strategy, competency, and capacity requirement for product/service • Conduct analysis for a technical approach to enterprise system structuring • Decide on a conceptual solution such as a job shop vs. a cellular shop • Furthermore, possible migrating from a job-shop structure to a cellular layout over time • Design an enterprise system structure • Enterprise structural design for physical, managerial, and computer systems • Enterprise component design for the three system elements • Develop an implementation plan for enterprise system structure • Implementation plan for physical, managerial, and computer systems structure • Implementation plan for physical, managerial, and computer systems component.