Project Management of Complex and Embedded Systems

by Kim H. Pries; Jon M. Quigley

• ISBN13: 9781420072068
• ISBN10: 1420072064
• Format: Nonspecific Binding
• Copyright: 2008-10-22
• Publisher: Taylor & Francis

Summary

There are many books on project management and many on embedded systems, but few address the project management of embedded products from concept to production. Project Management of Complex and Embedded Systems: Ensuring Product Integrity and Program Qualityuses proven Project Management methods and elements of IEEE embedded software development techniques, to explain how to deliver a reliable complex system to market. This volume begins with a general discussion of project management, followed by an examination of the various tools used before a project is underway. The book then delves into the specific project stages: concept, product development, process development, validation of the product and process, and release to production. Finally, post-project stages are explored, including failure reporting, analysis, corrective actions, and product support. The book draws heavily on information from Department of Defense sources as well as systems developed by the Automotive Industry Action Group, General Motors, Chrysler, and Ford to standardize the approach to designing and developing new products. These automotive development and production ideas have universal value, particularly the concept of process and design controls. The authors use these systems to explain project management techniques that can assist developers of any embedded system. The methods explored can be adapted toward mechanical development projects as well. The text includes numerous war stories offering concrete solutions to problems that might occur in production. Tables and illustrative figures are provided to further clarify the material. Organized sequentially to follow the normal life cycle of a project, this book helps project managers identify challenges before they become problems and resolve those issues that cannot be avoided.

Table of Contents

Projects and Project Managers

Delivery

Overview of Program/Project Management

Need for this Book

Comparison of Approaches

Automotive Industry Action Group

Department of Defense

Institute of Electrical and Electronics Engineers

Electronics Industry Association

Process Management Areas

Staged-Gate Methods in General

What is a Gate?

Reasons for Gate Reviews

Objectives

Gate Targets

Importance of Gate Targets Selection

Measurement of Targets (Statistics)

Example of a Phased Project

Project Management

People

Limited Resource

Project Manager's role

Organization and Integration

Customer Focus

Brainstorming

Technical Solutions

Quality

Facilitate Team Creation

Conflict Resolution

Product Development Team Meetings

Program Management

Embedded Development

Product Integrity and Reliability

Product Integrity

System-Level Testing

Reliability

Cost

Structure of Sections

Technical Tools

Delivery

Axioms of Program Management

Supplier Selection

Supplier Evaluation

Capability Maturity Model Integrated

Software Process Improvement and Capability dEtermination

Work Breakdown Structure

Resource Breakdown Structure

Project Estimating and Scheduling

Top Down Estimating

Bottom Up Estimating

Phased Estimating

Project Evaluation and Review Technique

CPM

Network Diagram in General

Constructive Cost Model II

Product Integrity and Reliability

Risk Management

Risk Taxonomy

Risk Methodology

Risk Quantification

Assessment of Product Risk

Simulation and Modeling

Verification

Validation

Stress Testing

Reliability Testing

Cost

Project Acceptance Criteria

Payback Period

Return on Investment (ROI)

IRR

Market Share

Project Cost Management

Earned Value Management

Budget Controls

Cost Performance Index

Schedule Performance Index

Cost Variance

Schedule Variance

Estimate at Completion

Estimate to Completion

Variance at Completion

Quality, Function, Deployment, and Cost Status

War Story

Human Resource

Systems Thinking

Project Manager Words

Concept

Concept Overview

Inception

Planning

Implementation

Regulation

Termination

Gate Targets - Past View

Gate Targets - Future View

Delivery

Work Descriptions

Project Charter

Statement of Work and Statement of Objectives

SOW Detail

Charters versus SOWs

Product Integrity and Reliability

Voice of the Customer

Quality Function Deployment

Requirements and Constraints matrix

Engineering Issues

Bills of Material (Engineering)

Change Management (Engineering)

Change Management (Project Management)

Material Specification

Engineering Specification

Customer Specification

Specification Reviews

Special Product Characteristics

Hardware Revision Levels

Production Issues

Bills of Material (Manufacturing)

Process Flow Diagram

Special Process Characteristics

Line Sequencing

Quality Issues

Quality Requirements

Reliability Requirements

Product Assurance Plan

Software Quality Assurance Plan

Cost

Request for Proposal

Contract Types (fixed, etc)

Pugh matrix - Concept selection

Crashing Program Definition

Program Definition Risk

Funding Risk

Reducing the Risk

Technical Risk Assessment

Reducing the Risk

Schedule Risk

Reducing the Risk

Management Support

War Story

Cutting Edge Components

Herding Cats

Product Development

Product Development Overview

Phase Objectives

Inception

Planning

Implementation

Regulation

Termination

Delivery

Crashing Product Development

Schedule Compression

Crashing Limitation

Crashing Risk

Fast Tracking

Fast Tracking Risk

Product Integrity and Reliability

Design Failure Mode and Effects Analysis (DFMEA)

Design For Manufacture and Assembly

Prototype Builds

Key Product Characteristics

Design Verification

Product Development Risk

Design Requirements Risk

Reducing the Risk

Design Policy Risk

Reducing the Risk

Design Process Risk

Reducing the Risk

Design Analysis

Reducing the Risk

Parts and Materials Selection

Reducing the Risk

Software Design

Reducing the Risk

Design Reviews

Reducing the Risk

Design Release

Reducing the Risk

Product Requirements Risk

New Equipment, Tooling, and Facility Requirements Gauges and Testing Equipment Requirements

Team Feasibility Commitment and Management Support

Cost

Request For Quote

Make or Buy Analysis

Value Analysis

What is Value Analysis?

Information Phase

Functional Analysis

Creative Phase

Judgment Phase

Development Phase

Recommendation Phase

Product Functional Decomposition

Value Analysis Integrated into Design Process

Outsourcing

Project Manager Involvement in Negotiations

Modular design

War Story

Production site

Material availability

Battery

Commitment

Process Development

Delivery

Process Development Overview

Phase Objectives

Initiate

Plan

Execute

Control

Closing

Product Integrity and Reliability

Process Flow

Ideal Process Flow

Less than Ideal Process Flow

Process Flow Under Control

PFMEA

Key Control Characteristics

PCP

Special Process Characteristics

Process Floor Plan

Process Flow Chart

Product and Process Quality System Review

Characteristics Matrix

Prelaunch Control Plan

Process Instructions

Measurement Systems Analysis Plan

Packaging Specifications and Standards

Corrugated Containers

Returnable Containers

Packing Slips

Preliminary Process Capability Study Plan

Crashing Process Development

Process Development Risk

Manufacturing Plan

Reducing the Risk

Quality Manufacturing Process

Reducing the Risk

Piece Part Control

Reducing the Risk

Supplier Control

Reducing the Risk

Defect Control

Reducing the Risk

Tool Planning

Reducing the Risk

Production Test Equipment

Reducing the Risk

Manufacturing Screening

Reducing the Risk

Process Capability

Cost

Cost and delivery performance

Modular design of process and equipment

Management Support

War Story

Validation of Product and Process

Delivery

Validation of Product and Process Overview

Phase Objectives

Initiate

Planning

Execute

Control

Closing

Product Integrity and Reliability

Design Verification Plan and Report

Verification versus Validation

Verification

Validation

Manufacturing Qualification

Electronic Data Interchange

Bench Testing versus Field Testing

Bench Testing

Final Product or Multievent Testing

Measurement Systems Evaluation

Preliminary Process Capability Study

Production Part Approval Process

Packaging Evaluation

Process Control Plan

Reduced Variation

Common Cause

Special Cause

Crashing Verification and Validation

Validation Risk

Built-In Test

Reducing the Risk

Cost

Outsourced

Simulation

War Story

Last Minute Material Failure

Component Qualification

Trust But Verify

PVT on Nonproduction Parts

Slow Testing Feedback

Errors Found in Production

Release to Production

Release to Production Overview

Phase Objectives

Inception

Planning

Implementation

Regulation

Termination

Delivery

Process Sign-Off

Trial Production Runs

Production Process Review

Process Verification Testing

First Time Capability

Quality Planning Sign-off

Pilot Runs

Goals

Objectives

Runs-at-Rate

Crashing Production Release

Methods Builds

Design Change Notification

Product Integrity and Reliability

Production Test Equipment

Production Release Risk

Service Parts

Reducing the Risk

Technical Documents

Reducing the Risk

Deviations

Cost

Delivery Performance

Design for Manufacture

Design for Assembly

War Story

Last Minute Material Failure

Failure Reporting and Corrective Action System (Phase)

Delivery

Importance of Failure Reporting, Analysis, and Corrective Action System

Initiate

Planning

Execute

Control

Closing

Product Integrity and Reliability

Risk

Failure Reporting System

Reducing the Risk

Cost

War Story

Unplug It

Product Support

Delivery

Project Management Responsibility

Handing off the Project

What Happens During launch

Crashing Product Support

Product Integrity and Reliability

Launch Containment

Cost

Extensibility

Emergency Shipment

War Story

Supplier/Customer relationship

Field Failure

Program Management

Program management versus Project Management Program Manager Skill Set

Final Thoughts

How Many Programs Work Concurrently?

Generalizing Automotive Techniques to Project Management

Future Trends

Globalization

Reduction in Force

Troubled Project

Project Manager Origins

"The Accidental Project Manager"

Technical Talent as Project Managers

Outsourcing Project Management

Importance of Lessons Learned

APPENDICES

The 18 PPAP Documents

System Requirements Review (SRR)

System Design Review (SDR)

Software Specification Review (SSR)

Software Quality Assurance Plan (SQAP)

Software and Hardware Reviews

Preliminary Design Review (PDR)

Critical Design Review (CDR)

Test Readiness Review (TRR)

Functional Configuration Audit (FCA)

Physical Configuration Audit (PCA)

Formal Qualification Review (FQR)

Production Readiness Review (PRR)

Embedded Development Overview

Process Sign-off

Software Metrics

Software Metrics

Project Metrics

IEEE-1220 Systems Engineering Master Plan Format

Release Notes

FMEA Basics

Bibliography

Index

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