Senior Design Lecture 5

1. Senior DesignLecture 5 Prototype phase Evaluation phase Production phase University of Portland School of Engineering

2. Milestones/ Approvals Product Approval Design Release Prototype Release Beta Release Product Release Define Prototype Design Not in class Evaluation Production EOL Debug & Evaluation Plan Functional Specifications Project Plan Qualification Report Manufacturing Report Documents Theory of Operations Final Report Product development cycle University of Portland School of Engineering

3. Any questions? • Definition phase • Functional Specifications document • Product Approval milestone • Design phase • Project Plan document • Design Release milestone University of Portland School of Engineering

4. Milestones/ Approvals Prototype Release Define Prototype Design Evaluation Production Debug & Evaluation Plan Documents Theory of Operations Prototype phase University of Portland School of Engineering

5. Prototype phase overview • Purpose • Integrate the pieces (big step) • Create the initial (alpha) version of the product • Documents • Debug & Evaluation Plan (testing methodology) • Theory of Operations (technical description) • Milestone: Prototype Release University of Portland School of Engineering

6. Debug & Evaluation Plan • Purpose • Defines who is doing what and when • Prove that design works and how well (robust) • Use (true for all plans) • Monitor and track progress, software database application • Identify schedule slips, budget overruns in advance University of Portland School of Engineering

7. Debug & Evaluation Plan, continued. • Issues • Poorly defined tests and minimal coverage • Bugs: repetitive/easy, intermittent/difficult, tracking • High demand for prototypes, little supply • Recommendation: plan debug and testing to take at least 2X the time expected University of Portland School of Engineering

8. Theory of operation • What: technical description of how the design works • Scope: focus on the internal workings • Your TOP’s: if you can describe it, you can’t debug it University of Portland School of Engineering

9. How is a TOP’s used? • Egr- what they’re doing • Mktg- advertising • Mfg- understand the technologies • Service- help explain to customers • Sales- understand their market • Sr. Mgmt- waste basket liner • Finance- another liner University of Portland School of Engineering

10. Prototype Release (Alpha Release) • Purpose • Start thorough testing • Begin to deploy product to stakeholders (little value earlier) • Process • Hold an approval meeting: team, advisor, industry rep • Demonstrate working prototype University of Portland School of Engineering

11. Milestones/ Approvals Beta Release Define Prototype Design Evaluation Production Qualification Report Documents Evaluation Phase University of Portland School of Engineering

12. Evaluation phase overview • Purpose • Prove that design works and how well (robust) • Finalize design for high-volume production • Documents • Qualification Report (data, analysis, conclusions) • Physical evidence • Milestone: Beta Release University of Portland School of Engineering

13. Why an evaluation phase? • Get rid of bugs • Make sure it works • Quality, defects University of Portland School of Engineering

14. Bug tracking • States/dates: open, study, fixed, tested, etc., closed • Severity: H, M, L • Metrics • Number of bugs, bugs vs. time • Number of high’s, high’s vs. time • High’s open a long time • War Room University of Portland School of Engineering

15. Example bug tracking application University of Portland School of Engineering

16. Pentium evaluation • Number of engineers? • Time frame? • Number of bugs tracked? University of Portland School of Engineering

17. Qualification Report • Purpose: document qualification • What: testing methods, data, analysis • Issues • Poorly defined data & methods & conclusions • Impossible to reproduce data • Major document, tons of data, shared with stakeholders University of Portland School of Engineering

18. How is a Qual Report used? • Egr- fix stuff • Mktg- hide/document flaws • Mfg- tools are working • Service- predict problems • Sales- ? • Sr. Mgmt- who to fire • Finance- over budget University of Portland School of Engineering

19. Beta Release • Purpose • Begin widespread prototype deployment • Start manufacturing ramp-up • Process • Checklists work well • Include peer & expert reviewers University of Portland School of Engineering

20. Milestones/ Approvals Product Release Define Prototype Design Evaluation Production Manufacturing Report Documents Production (Ramp-Up) Phase University of Portland School of Engineering

21. Production phase overview • Purpose: ramp the manufacturing line up to full-scale production, take dpm data • Documents • Manufacturing Report • Demonstrates manufacturability • Milestone: Production Release, PR (first customer ship-FCS) University of Portland School of Engineering

22. How is a mfg report used? • Egr- • Mktg- • Mfg- • Service- • Sales- • Sr. Mgmt- • Finance- University of Portland School of Engineering

23. Production Release • Purpose • Begin high-volume production, bring in revenue ($$) • Post-mortem held to discover learning’s • Process: Often requires a risk assessment & judgment call by senior management University of Portland School of Engineering

24. University of Portland School of Engineering

25. How is a TOP’s used? • Egr- debug • Mktg- customer mtgs • Mfg- plant layout, testing • Service- maintenance guide, training • Sales- customer mtg • Sr. Mgmt- sales • Finance- None University of Portland School of Engineering

26. Why an evaluation phase? • Make sure it works • Discover bugs/fix them • Identify weak points for future enhancements • Push product to limits (robust) • Make sure designed the right thing University of Portland School of Engineering

27. Pentium evaluation • Number of engineers? 300 - 400 • Time frame? 9 months • Number of bugs tracked? 300 - 500 University of Portland School of Engineering

28. How is a Qual Report used? • Egr- Baseline product performance, submit for certifications (UL, CSA, VDE, software) • Mktg- Share with customers for cross-quals • Mfg- Validate testing • Service- Estimate failure rates (fit’s) • Sales- Create promotional literature • Sr. Mgmt- IP, legal • Finance- None University of Portland School of Engineering

29. How is a mfg report used? • Egr- Adjust design guidelines • Mktg- Product planning • Mfg- Estimate defects-per-million (dpm) • Service- Cost of spares • Sales- None • Sr. Mgmt- Future plant planning • Finance- Validate ROI assumptions, analysis University of Portland School of Engineering