Project ManagementJan 27, 2006

James R. MattTechnical Fellow

General Motors Corp

“I think there is a world market for maybe five computers.”

-- Thomas Watson, chairman of IBM, 1943

Conventional Wisdom: A Rogue’s Gallery

“There is no reason anyone would want a computer in their home.”

Ken Olson, President, Chairman and Founder of Digital Equipment Corp., 1977

“640K ought to be enough for anybody.”Bill Gates, 1981

“What do 13 people in Seattle know that we don’t?”

Ross Perot when presented with a proposal for EDS to acquire Microsoft, 1980

Key Thoughts & Simple Tools

Coarse to FineProduct Development

Needs&

Ideas

Organize& Prioritize

SelectProof of Concept

TechnicalSolution

Development

ProductionReadiness

Manufacturing&

Production

Customer and Market Feedback

(data from: Marketing, Sales, Quality, Benchmarking, Customers)

Spider Chart Performance Targets and Key Wins

Today’s Product or Situation

Best in Class CompetitionTargets for new Design

Key Wins

FasterSpeed

SmallerSize

Durability Life

Trade-off study matrix

Desig

n

Op

tion

#1

Desig

n

Op

tion

#2

Desig

n

Op

tion

#3Example Criteria

Performance

Cost

Mass

Quality

Volume / Size

Risk

Durability

Summation

Key: “++” = Much Better

“+” = Somewhat Better

“0” = No Improvement

“-” = Worse

“ - - ”= Much Worse

Trade-off study matrix

Desig

n

Op

tion

#1

Desig

n

Op

tion

#2

Desig

n

Op

tion

#3Example Criteria

Performance

Cost

Mass

Quality

Volume / Size

Risk

Durability

++

++

++

++- -

- -

0

-

+

+

0

-

+

+

+

+

0

0

0

++

-

Summation +1 +5 +3

Key: “++” = Much Better

“+” = Somewhat Better

“0” = No Improvement

“-” = Worse

“ - - ”= Much Worse

Engineering Project Management

Phase 00Phase 00Define

Requirements, Key Interfaces,& Constraints

Concepts Generate Detail

Concept

Product Development

Approve ProjectPlan, Team, and & Deliverables

RequirementsAgreement

Select & Approve Design

Concept

1 2

ApproveDetail Concept

43

Optimize &

Verify

ApproveConcept

Verification

5

Technology Planning

Determine Needs, Select Projects.& Assign Teams

I - IdentifyD1

Define Requirements

D2 – Design Concept

O - Optimize

V - Verify

DFSS ‘ IDDOV & Product Development

Design for Six Sigma IDDOV

Phase 00Phase 00Define

Requirements, Key Interfaces,& Constraints

Product Development

Approve ProjectPlan, Team, and

& Deliverables

1 2 43 5

Technology Planning

Determine Needs, Select Projects.& Assign Teams

Project Tasks and Gate Reviews

Tasks:•Determine Perf & Manf Requirements

•Define Business Targets

•Define Needs

•

Review with key Stakeholders

•

Develop Commercial Approach

•

Define Project Plan & Resources Required

Tasks:

•Establish Project Plan

•Obtain Lessons Learned

•Draft Initial Specifications

•Define Interfaces, Constraints

•Gather Information todetermine Requirements

•Conduct Gate Review #1

Tasks:•Generate & Assess Alternative concepts

•Perform Evaluations

•Concept Tradeoff Study

•Refine Specifications & Robust Eng Plan (DOE)

•Conduct Concept Reviewand Approve Design Concept

Tasks:•Develop purchasing info

•Conduct Robust assessment•Optimize Concepts

•Conduct Peer Review

•Update all Business, Technical, and Project Documents

•Approve Details ConceptMake Purchasing Decisions

Tasks:•Develop Design

•Finalize Development &Test Plan

•Construct, Build, and Test Prototype

•Verify Hardware, Softwareto Technical Requirements

Conduct Final DesignReview

•Update all Business & Technical Documents

Define Requirements Key Interfaces & Constraints

Concept Generation & Design Selection

Robust Assessment & Purchasing

Optimize & ValidateDefine Initial Project

•

RequirementsAgreement

Select & Approve Design

Concept

ApproveDetail Concept

ApproveConcept

Verification

Concepts Generate Detail

Concept

Optimize &

Verify

Five Objectives of Every Project Gate Review

1) Explain the Benefits of the Technical Solution or Technology

2) Show the Technical Feasibility of approach and solution

3) Show the Balance of Performance to Business Imperatives

4) Explain the Risks:a) Business.b) Application Timing.c) Technical.

5) Explain the Expected Engineering Expenses & Costs.

Risk

‘Risk’ Types of Risk (things gone ‘wrong’, or critical items not going ‘right’)

• Business• Timing• Technical

Quantify Relative Risk

Risk f(L,M) = (Likelihood) X (Magnitude)

Method1. Brainstorm Potential Problems2. Define Likelihood of Occurrence (1 -10 scale)3. Define Magnitude should problem occur (1-10 scale)4. (Risk Priority Number) RPN = (Likelihood) X (Magnitude)5. Rank order into a bar chart (Pareto Diagram)6. Define Countermeasures

Pareto Diagram

RPN(Risk

PriorityNumber)

Specific Potential Problems

Focus on the high RPN Risk items and put in place Countermeasures

Must Insure --‘Bang for the Buck’(limited resources cause the need to Focus)

Lower

Higher

Modularity & Standard Parts as Risk Reduction

Component Design & Build Approach

TransferFunction

InputIntendedOutput

Risk:Output not Design Intent

Component Design & Build Approach

TransferFunction

Input

IntendedOutput

Risk:Unintended Interactions

TransferFunction

Input

Independent Component Design & Build Approach

Component Design & Build Approach

Modular Build Approach

Sub-assembled & Pre-Tested Modules

Modular Build Approachwith Standard Parts

Using Standard Parts

ExampleHeadlamp & Turn Signal

Multifunction Electrical Switch

5 Phase Problem Resolution

1. Problem Definition

2. Containment, Immediate Corrective Action

3. Root Cause

4. Irreversible Corrective Action

5. Verification

ExampleMultifunction Headlamp Switch

HeadlampOn / Off

HeadlampHigh / Low

Turn Signal

Cruise ControlSet, On, Off

Customer Electrical Control

Component test plan was designed to test each function

as independent variables

All part passed the lab test without incident

Functions

HeadlampOn / Off

HeadlampHigh / Low

Turn Signal

Cruise ControlSet, On, Off

Customer Electrical Control

However:Mechanical Interaction Inside theMultifunction Switch caused the

headlamp contact carrier to slightly rock when the Turn Signal was used.

This caused a voltage spike and high resistance path and heat in the switch.

Functions

ExampleMultifunction Headlamp Switch

ExampleMultifunction Headlamp Switch

HeadlampOn / Off

HeadlampHigh / Low

Turn Signal

Cruise ControlSet, On, Off

Customer Electrical Control

DOE factors for test matrix1) Type of Lubricant in the switch2) Contact Material 3) Contact Plating4) Spring Pressure

The optimal combination was found and the design was quickly changed.No field issues were found

ExampleUpper Strut Mount

Design For Six Sigma Example

Define the Basic Functions

• Brainstorm a list of Basic Functions the Product must provide. “What does this thing need to do?”– Use Verbs:

• React• Position• Isolate• Filter• Rotate• Limit• Amplify• etc

Consider Classis Failure Mechanism that Cause Failure Modes

• Creep • Fracture • Yield • Physio-Chemical Instability • Dimensional Incompatibility • Contamination • Vibration and Mechanical Shock • Environmental • Wear

Consider Classis Failure Mechanism that Cause Failure Modes

• Creep (relaxation and flow over time, plastic movement, often accelerated with heat or high loads)

• Fracture (brittle failure due to sudden physical overload, cracking)• Yield (Tensile or bending failure, permanent deformation)• Physio-Chemical Instability (Chemical change in material

properties, Corrosion, UV instability, chemical attack of solvent or lubricants, heat aging of rubber)

• Dimensional Incompatibility (Stack up of tolerances, mis-positioning, flexing of base or bracket, too big, too small)

• Contamination (dirt, grit, dust, mixed materials)• Vibration and Mechanical Shock (mechanical or electrical

high frequency, surge, sudden overload)• Environmental (hot, cold, humid, submersion)• Wear (repeated cyclic load causing material removal)

Matrix Functions vs Failure Mechanisms – Evaluate Risk due to Sensitivities

Cre

ep

Frac

ture

Yie

ld

Phy

sio

-Che

mic

al In

stab

ility

Dim

ensi

onal

Inco

mpa

tibili

ty

Con

tam

inat

ion

Vib

ratio

n an

d M

echa

nica

l Sho

ck

Env

iron

men

tal

Wea

r

React

Position

Isolate

Filter

Rotate

Limit

Amplify

Functions

Failure Mechanisms

Matrix Functions vs Failure Mechanisms – Evaluate Risk due to Sensitivities

Cre

ep

Frac

ture

Yie

ld

Phy

sio

-Che

mic

al In

stab

ility

Dim

ensi

onal

Inco

mpa

tibili

ty

Con

tam

inat

ion

Vib

ratio

n an

d M

echa

nica

l Sho

ck

Env

iron

men

tal

Wea

r

React

Position

Isolate

Filter

Rotate

Limit

Amplify

High

High

High

High

Med

Med

Matrix Assessment – Knowledge Gathering

Position

Stays in place over life

Tolerant of misaligned mating parts

Isolate

Quiet over life

Noise Transmission is good

React Loads

Rate Curve is within Bandwidth

Structure handles load with out excessive Damage

(Failure Mechanisms cause Failure Modes)Environment

ContaminationYield

FatigueFracture

Vibration / Mechanical ShockWear

Electrical / Software CompatibilityPhysio-Chemical Instability

CreepDimensional Incompatibility

DFSS - Front Upper Strut Mount

Noise Factors

Functions:Position,Isolate,

React Loads

Energy Desired Functional Characteristic

Noise Factors

Functions:Position,Isolate,

React Loads

Energy Primary Function

The Forward Pass

Position

Isolate

React Loads

Fai

lure

Mec

han

ism

s E

nvi

ron

men

tC

onta

min

atio

nY

ield

Fra

ctu

reV

ibra

tion

/ M

ech

anic

al S

hoc

kW

ear

Ele

ctri

cal /

Sof

twar

eP

hys

io-C

hem

ical

In

stab

ilit

yC

reep

Dim

ensi

onal

In

com

pat

ibil

ity

Primary FunctionsLikelihood: of compromise of a “Primary Function” due to a Sensitivity to “Failure Mechanism”.Strong Likelihood = “ + ”Neutral = “ 0 ”Not Sensitive = “ – ”

Functions:Position,Isolate,

React Loads

Anticipated or

Historic Problems

The Reverse Pass learn for what has happened before

Noise Factors

Chart the probability of each Failure Mechanism contributing to historic problems and loss of desired Functions

Failure Mechanisms Environment

ContaminationYield

Fracture Vibration / Mechanical Shock

WearElectrical / Software

Physio-Chemical InstabilityCreep

Dimensional Incompatibility

In this case, Contamination, Yield, Wear, and Dimensional Incompatibility are the high Occurrence Failure Mechanism that are anticipated as the dominate Noise factors.

Functions:Position,Isolate,

React Loads

EnergyDesired Functional Characteristic

Anticipated Problems

Forward Pass

Reverse Pass

Now think in terms of the design Components (and for competing design options)

A – Inner Metal B – Primary/Shear IsolatorC – Upper Rate WasherD – Reaction WasherE – Reaction IsolatorF – Outer/Compression IsolatorG – Main StampingH – Lower Rate Washer

A

B

C

D E

F

G

H

Top Mount Bearing

DOE:•Partial Factorial Matrix experiment

•Expert Knowledge, seek help in creation•Garbage in Garbage out (usually due to bad assumptions)

•Want a simple lab fixture(s) to run a fast DOE to understand design sensitivity to Noise factors.•Run carefully Created samples to test for interactions

Failure Mechanisms Contamination

WearPhysio-Chemical Instability

Dimensional Incompatibility

Pos

itio

n

Isol

ate

Rea

ct L

oad

s

Noi

se a

t th

e en

d o

f li

fe

Los

s of

att

ach

men

t

Bea

rin

g D

rag

Non

-lin

ear

road

fee

l

X

X

X

XX X

Basic Principles – Friction, transient loads, moments, unforeseen interactions, manufacturing processes capabilities, marginally stable systems, static electricity, grounding

Wrong Assumptions (independence of functions in switch example)

Lack of parts available on time

Components cost more than estimated

Stack up of tolerances – reality is not design nominal

Murphy’s Law, Chaos Theory, probability and statistical theory at work

False or unachievable accuracy

Causes of Problems

Idea GenerationDo not jump to conclusions or select your mainstream concept too quickly. Brainstorm, talk to experts, consider viability of alternatives, carefully select your mainstream direction based on Tradeoffs.

ExecutionSet up a good project plan with Milestones and Gate Reviews

Clearly defined Deliverables

Set up a budget (with a 10% contingency) and obtain good cost estimates and availability of materials, manpower, and facilities

Front Load your efforts – get off to a good start

Assign tasks to team members based on skill sets and personal preferences. Monitor progress, keep things visible.

Design and Build Modules where practical.

Use Standard parts and commonly available materials

Allow time for experimentation and ‘Slack time’ for things to go wrong in build & test.

Do your homework

Helpful Ideas & Thoughts

Closing Thoughts

Good LuckGet Started

Have Fun& Expect Things to go Wrong