T2-3: Engineering process

T2-3: Engineering processT2-3: Engineering process

Chin-Sheng ChenChin-Sheng ChenFlorida International UniversityFlorida International University

T2-3: Engineering T2-3: Engineering processprocess Engineering processEngineering process

– Need and specificationNeed and specification– Modeling and analysisModeling and analysis– Functional designFunctional design– Implementation designImplementation design

The ESE Framework –The ESE Framework –Re-visitRe-visitEnterprise Enterprise elementelement

WorkWork DecisionDecision ResourceResource InformatioInformationn

System System facetfacet

StrategyStrategy CompetenCompetency cy (capability(capability))

Capacity Capacity StructureStructure

EngineerinEngineering activityg activity

SpecificatioSpecificationn

AnalysisAnalysis DesignDesign implementimplementationation

PerformanPerformance ce measuremeasure

QualityQuality TimeTime CostCost Benefit Benefit (profit)(profit)

Readings & ReferencesReadings & References

Readings:Readings:– HEA: Chapter 2HEA: Chapter 2

ReferenceReference– Product design and developmentProduct design and development by by

Karl Ulrich and S. Eppinger, McGraw-Karl Ulrich and S. Eppinger, McGraw-Hill, 2002Hill, 2002

Engineering process – Engineering process – need and specification need and specification (1)(1) Need, definitionNeed, definition

– An attribute of a potential system (product) that is An attribute of a potential system (product) that is desired by the customer.desired by the customer.

– Other names: customer attributes, customer Other names: customer attributes, customer requirementsrequirements

Guideline for need statementsGuideline for need statements– Express the need in terms of what the system (product) Express the need in terms of what the system (product)

has to do, not how.has to do, not how.– Express the need as specific as possibleExpress the need as specific as possible– Use positive, not negative phrasingUse positive, not negative phrasing– Express the need as an attribute of the system (product).Express the need as an attribute of the system (product).– Avoid using the words must and should.Avoid using the words must and should.– Organize needs into a hierarchy Organize needs into a hierarchy – Establish their relative importanceEstablish their relative importance

Engineering process – Engineering process – need and specification need and specification (2)(2)

Specification, definitionSpecification, definition– A precise description of what the system A precise description of what the system

(product) has to do.(product) has to do.– A specification has a metric and a value. A A specification has a metric and a value. A

value may take on several forms such as a value may take on several forms such as a number or a range.number or a range.

– A A specificationsspecifications is a set of the individual is a set of the individual specifications.specifications.

– Other terms used: Other terms used: system (product) requirements, engineering system (product) requirements, engineering

characteristics, technical specifications characteristics, technical specifications

Engineering process – Engineering process – need and specification need and specification (3)(3) Specification types:Specification types:

Target specifications:Target specifications:– Preliminary, ideal specificationsPreliminary, ideal specifications

Final specifications (in the contract book)Final specifications (in the contract book)– Final specifications depend on Final specifications depend on

what customers needs, what customers needs, what is technical and economic feasible what is technical and economic feasible

andand what our competitors offer in the market what our competitors offer in the market

place.place.

Engineering process – Engineering process – need and specification need and specification (4)(4) MetricsMetrics

– The most useful metrics are those that The most useful metrics are those that reflect as directly as possible the degree to reflect as directly as possible the degree to which the system (product) satisfies the which the system (product) satisfies the customer need.customer need.

– Metrics must be precise and measurable Metrics must be precise and measurable such that meeting specifications lead to such that meeting specifications lead to satisfaction of the related customer needssatisfaction of the related customer needs

– A need may be translated into more than A need may be translated into more than one metrics, and one metrics may satisfy one metrics, and one metrics may satisfy one or multiple needs. one or multiple needs.

Engineering process – Engineering process – need and specification need and specification (5)(5) Setting metrics valueSetting metrics value

– Competitive benchmarkingCompetitive benchmarking– Set ideal and marginally acceptable Set ideal and marginally acceptable

targettarget– Develop technical and economic Develop technical and economic

models to assess feasibility models to assess feasibility – Use the above data to create Use the above data to create

competitive maps and conduct trade-competitive maps and conduct trade-off analysisoff analysis

Engineering process – Engineering process – need and specification need and specification (6)(6) Hierarchy of system specificationsHierarchy of system specifications

– Each system (product) may have a Each system (product) may have a hierarchy of subsystems (products). hierarchy of subsystems (products).

– Each subsystem has its specificationsEach subsystem has its specifications– Therefore, the overall specifications for Therefore, the overall specifications for

the system must be decomposed (or the system must be decomposed (or flowed down) to hierarchical sets of flowed down) to hierarchical sets of specifications, one for each subsystem.specifications, one for each subsystem.

Engineering process – Engineering process – modeling and analysis modeling and analysis (1)(1) Model, definitionModel, definition

– Analytical or physical approximation of the system Analytical or physical approximation of the system (product), used as a tool for predicting the values of the (product), used as a tool for predicting the values of the metrics for a particular set of design decisionsmetrics for a particular set of design decisions

– Models can be focused or comprehensive, depending on Models can be focused or comprehensive, depending on the degree to which they implement all of the attributes of the degree to which they implement all of the attributes of the system (product). the system (product).

– Various models (including prototypes) may be developed to Various models (including prototypes) may be developed to support the engineering process including system support the engineering process including system specification, engineering analysis, functional design, and specification, engineering analysis, functional design, and implementation design.implementation design.

– Modeling:Modeling: the process for creating a model that reflects a desired system the process for creating a model that reflects a desired system

representation for understanding, assessment, and/or representation for understanding, assessment, and/or communication.communication.

Two well-known models: AS-IS and TO-BE.Two well-known models: AS-IS and TO-BE.

Engineering process – Engineering process – modeling and analysis modeling and analysis (2)(2) Analysis, Def.Analysis, Def.

– An engineering activity that uses a mathematical An engineering activity that uses a mathematical means or an engineering tool (such as a system or its means or an engineering tool (such as a system or its model) tomodel) to

understand and assess its behaviors andunderstand and assess its behaviors and Determine its desired end and the most efficient method Determine its desired end and the most efficient method

of obtaining this (that is, to seek an optimal technical of obtaining this (that is, to seek an optimal technical solution)solution)

– It may be exercised in all engineering phases.It may be exercised in all engineering phases.– Engineering analysis types:Engineering analysis types:

A technical decision forA technical decision for– A specificationA specification– A system (product) solution approachA system (product) solution approach– A functional designA functional design– An implementation designAn implementation design

Engineering process – Engineering process – modeling and analysis modeling and analysis (3)(3) Engineering analysisEngineering analysis

– ESE focusESE focus The system level of engineering analysisThe system level of engineering analysis

– The ESE analysis activity at system levelThe ESE analysis activity at system level Input: Input:

– System (product) specificationsSystem (product) specifications Output: Output:

– A technical solution approachA technical solution approach A conceptual design, for exampleA conceptual design, for example

Engineering process – Engineering process – modeling and analysis modeling and analysis (4)(4) Example of engineering analysis IExample of engineering analysis I

– A die design:A die design: Analysis issue: whether to use a progressive die or engineering Analysis issue: whether to use a progressive die or engineering

dies.dies. Technical solution approach: use a sequence of engineering diesTechnical solution approach: use a sequence of engineering dies Output: the WIP shape and size specification for each Output: the WIP shape and size specification for each

engineering die and its QA guidelines.engineering die and its QA guidelines.

Example of engineering analysis IIExample of engineering analysis II– An enterprise system designAn enterprise system design

Analysis issue: whether to use client-server or web-based systemAnalysis issue: whether to use client-server or web-based system Solution: use a hybrid approach of client-server and web-based.Solution: use a hybrid approach of client-server and web-based. Output: Interface and response time specifications. Output: Interface and response time specifications.

Engineering process – Engineering process – functional design (1)functional design (1) Functional design, def.Functional design, def.

– An activity that translates a conceptual design into an An activity that translates a conceptual design into an engineered system (product) design which meets the engineered system (product) design which meets the functional requirements as specified.functional requirements as specified.

– It should include industrial design, such asIt should include industrial design, such as use interface design and usabilityuse interface design and usability Security and safety designSecurity and safety design

Functional design typesFunctional design types– Architectural designArchitectural design

System architectureSystem architecture Subsystems architectureSubsystems architecture

– Components designComponents design

Engineering process – Engineering process – functional design (2)functional design (2) Architecture, DefArchitecture, Def

– A drawing (or structure) of somethingA drawing (or structure) of something– A representation of all the processes A representation of all the processes

involved in the life cycle of the involved in the life cycle of the something.something.

System architecture, Def.System architecture, Def.– A scheme by which the functional elements of the A scheme by which the functional elements of the

system are arranged into physical blocks and by system are arranged into physical blocks and by which the blocks interact.which the blocks interact.

Engineering process – Engineering process – functional design (3)functional design (3) Architectural design output (product)Architectural design output (product)

– Geometric layoutGeometric layout Assembly modelAssembly model Bill of Materials (BOM)Bill of Materials (BOM)

– RelationshipsRelationships Fundamental interactionsFundamental interactions Incidental interactionsIncidental interactions

– Flow designs:Flow designs: Coolant flows, Coolant flows, Mechanical & electrical flowsMechanical & electrical flows Material channels (runways)Material channels (runways)

Engineering process – Engineering process – functional design (4)functional design (4) Architectural design output (physical Architectural design output (physical

system)system)– Geometric layoutGeometric layout

Plant layoutPlant layout List of plant componentsList of plant components

– RelationshipRelationship Fundamental interactionsFundamental interactions Incidental interactionsIncidental interactions

– Flow designs:Flow designs: Aisles, staircases, driveways, conveyersAisles, staircases, driveways, conveyers

Engineering process – Engineering process – functional design (5)functional design (5) Architectural design output (Computer/ Architectural design output (Computer/

Management Systems)Management Systems)– Layout designLayout design

Menu layout (organization chart)Menu layout (organization chart) Listing of menu items (components)Listing of menu items (components)

– Relationship designRelationship design– Flow designFlow design

information and work flowsinformation and work flows Business processesBusiness processes Communication channelsCommunication channels

Engineering process – Engineering process – functional design (6)functional design (6) Components designComponents design

– For productFor product Competency and specificationsCompetency and specifications 2D/3D part drawings2D/3D part drawings

– For physical systemFor physical system Competency and specificationsCompetency and specifications 2D/3D component drawings2D/3D component drawings

– For managerial systemFor managerial system Competency and specifications Competency and specifications functional procedures and diagrams, flowcharts, formulas, report, functional procedures and diagrams, flowcharts, formulas, report,

etc.etc.– For computer systemFor computer system

Competency and specificationsCompetency and specifications Detailed object models, dynamic models, Detailed object models, dynamic models, functional procedures and diagrams, flowcharts, formulas, report, functional procedures and diagrams, flowcharts, formulas, report,

etc.etc.

Engineering process – Engineering process – functional design (7)functional design (7)

The three system layers - revisitThe three system layers - revisit– Physical systemPhysical system

Management systemManagement system– Computer management systemComputer management system

Engineering process – Engineering process – implementation design implementation design (1)(1) Implementation designImplementation design

– Implementation approachImplementation approach– System-wide implementation planSystem-wide implementation plan– Detailed implementation planDetailed implementation plan

Deployment designDeployment design– Deployment approachDeployment approach– (Process modeling and analysis)(Process modeling and analysis)– Installation process designInstallation process design– Training designTraining design– Data migration designData migration design– Validation designValidation design– Switch-over designSwitch-over design

Engineering process – Engineering process – implementation design implementation design (2)(2) For product designFor product design

– Technical solution approachTechnical solution approach Manufacturing technologyManufacturing technology

– For example, material deformation (casting, For example, material deformation (casting, molding, die-forming, crystal growing, etc.), molding, die-forming, crystal growing, etc.), removal (machining), or joining (welding)removal (machining), or joining (welding)

– System-wide implementation planSystem-wide implementation plan Assembly process plansAssembly process plans

– Component implementation planComponent implementation plan Component process plansComponent process plans

Engineering process – Engineering process – implementation design implementation design (3)(3) For physical system designFor physical system design

– Technical solution approachTechnical solution approach Implementation technologyImplementation technology

– For example, use modular or integrated For example, use modular or integrated approachapproach

– System-wide implementation planSystem-wide implementation plan High-level project action planHigh-level project action plan

– Component implementation planComponent implementation plan Component process plansComponent process plans

Engineering process – Engineering process – implementation design implementation design (4)(4) For managerial systems designFor managerial systems design

– Technical solution approachTechnical solution approach Implementation technologyImplementation technology

– For example, use modular or integrated For example, use modular or integrated approachapproach

– System-wide implementation planSystem-wide implementation plan System-level implementation planSystem-level implementation plan

– Component implementation planComponent implementation plan Component implementation planComponent implementation plan

Engineering process – Engineering process – implementation design implementation design (5)(5) For computer system design (1)For computer system design (1)

– Technical solution approachTechnical solution approach Implementation environment & toolsImplementation environment & tools

– For coding: C++ vs. JavaFor coding: C++ vs. Java– For structure: 3-layer vs. integratedFor structure: 3-layer vs. integrated


– System-wide implementation planSystem-wide implementation plan Project managementProject management

– Change management and version controlChange management and version control– Packaging and installation processPackaging and installation process

System implementation planSystem implementation plan– Guidelines for code structure, user interface design and Guidelines for code structure, user interface design and

documentationdocumentation– Library of system standard componentsLibrary of system standard components

TestingTesting– Test policy and guidelinesTest policy and guidelines– Classes of testsClasses of tests– Expected software responsesExpected software responses– Performance boundsPerformance bounds– Identification of critical componentsIdentification of critical components

System debuggingSystem debugging– Policy and strategyPolicy and strategy


– Component implementation planComponent implementation plan Flow implementation designFlow implementation design

– Program interface, flowchart, variables, parameters.Program interface, flowchart, variables, parameters. User interface implementation designUser interface implementation design

– Interface details, messages design, on-line help & Interface details, messages design, on-line help & searchsearch

– Form designForm design– Data design (internal, global and temporary data Data design (internal, global and temporary data

structure in implementation, & variable conventions)structure in implementation, & variable conventions) Software interfaceSoftware interface

– Machine interface and system interfaceMachine interface and system interface Database implementation designDatabase implementation design

– Table list, definition, and relationshipTable list, definition, and relationship

Engineering process – Engineering process – implementation design implementation design (8)(8) Deployment design (1)Deployment design (1)

– Deployment approachDeployment approach Unit by unit, or function by functionUnit by unit, or function by function Top down or bottom upTop down or bottom up

– Installation (upgrade) process designInstallation (upgrade) process design Automatic or manualAutomatic or manual

– Training process designTraining process design Development of use casesDevelopment of use cases Training programmingTraining programming

– by unit or by functionby unit or by function– Top down or bottom upTop down or bottom up

Online trainingOnline training

Engineering process – Engineering process – implementation design implementation design (9)(9) Deployment design (2)Deployment design (2)

– Data migration/entry process designData migration/entry process design Automatic or manual entryAutomatic or manual entry

– Validation process designValidation process design by phase or one timeby phase or one time

– Switch-over process designSwitch-over process design Gradual or one timeGradual or one time

Engineering process – Engineering process – with focus onwith focus on methods and methods and techniques (1)techniques (1) ESE is different from other enterprise ESE is different from other enterprise

system-related efforts in its emphasis system-related efforts in its emphasis for development and application of for development and application of methods and techniques to each methods and techniques to each engineering activity. They are:engineering activity. They are:

Specification methods and techniquesSpecification methods and techniques Modeling and analysis methods and techniquesModeling and analysis methods and techniques Design and optimization methods and techniquesDesign and optimization methods and techniques Implementation planning methods and Implementation planning methods and

techniquestechniques

Engineering process – Engineering process – activity methods and activity methods and techniques (2)techniques (2) Enterprise strategy engineering Enterprise strategy engineering

process process 1.1. Create (specify) strategic identityCreate (specify) strategic identity

2.2. Conduct strategic analysisConduct strategic analysis

3.3. Formulate (design) strategyFormulate (design) strategy

4.4. Develop strategy implementation planDevelop strategy implementation plan


process (1)process (1)– Create the strategic identityCreate the strategic identity

Define a missionDefine a mission Develop a visionDevelop a vision Declare strategic intentDeclare strategic intent Identify core work (product/service)Identify core work (product/service)


process (2)process (2)– Conduct strategic analysisConduct strategic analysis

Develop an industry foresightDevelop an industry foresight Identify current market, product/service Identify current market, product/service

and resource conceptsand resource concepts (Identify required new competencies)(Identify required new competencies)


process (3)process (3)– Design (formulate) strategyDesign (formulate) strategy

(Develop a balanced portfolio of (Develop a balanced portfolio of capabilities)capabilities)

(Develop a resource and capability (Develop a resource and capability acquisition agenda)acquisition agenda)

Strategically position the companyStrategically position the company Create generic product strategiesCreate generic product strategies Develop generic market strategiesDevelop generic market strategies


processprocess– Design (formulate) strategy (3-1)Design (formulate) strategy (3-1)

Strategically position the company (as a Strategically position the company (as a prospector, analyzer, defender or prospector, analyzer, defender or reactor), according to:reactor), according to:

– Org. readiness for risk takingOrg. readiness for risk taking– Readiness for developing new productsReadiness for developing new products– Technological orientationTechnological orientation– Administrative orientation (type of company Administrative orientation (type of company

control) control)

Engineering process – Engineering process – activity methods and activity methods and techniques (7)techniques (7) Enterprise strategy engineering processEnterprise strategy engineering process

– Design (formulate) strategy (3-2)Design (formulate) strategy (3-2) Create generic product strategiesCreate generic product strategies

– Low cost or price differentiationLow cost or price differentiation– Image differentiation (distinctive design)Image differentiation (distinctive design)– Support differentiation (after-sales service)Support differentiation (after-sales service)– Quality differentiation Quality differentiation – Design differentiation (added, improved Design differentiation (added, improved

production functionality)production functionality)– Penetration strategyPenetration strategy– Bundling strategyBundling strategy– Market, product and diversification strategiesMarket, product and diversification strategies


processprocess– Design (formulate) strategy (3-3)Design (formulate) strategy (3-3)

Develop generic market strategiesDevelop generic market strategies– Size and diversitySize and diversity– Location (local, regional, national, global)Location (local, regional, national, global)– Stage of evolutionStage of evolution

Emerging marketEmerging market Established marketEstablished market Eroding marketEroding market Erupting marketErupting market


– Develop strategy implementation plan (4-1)Develop strategy implementation plan (4-1) Plan to articulate and codify strategy, by Plan to articulate and codify strategy, by

translating it intotranslating it into– Strategic visionStrategic vision– Strategic objectivesStrategic objectives– Key success factorsKey success factors– (Key performance indicators)(Key performance indicators)– (Key personal performance indicators)(Key personal performance indicators)

Plan to evaluate strategyPlan to evaluate strategy– For consistency, consonance, advantages, and For consistency, consonance, advantages, and

feasibilityfeasibility


– Develop strategy implementation plan (4-2)Develop strategy implementation plan (4-2) Plan to elaborate strategyPlan to elaborate strategy

– Transform the strategy into executable and operational Transform the strategy into executable and operational plans in strategic and annual plansplans in strategic and annual plans

Plan to promote strategyPlan to promote strategy– To be advertised, debated, understood, and accepted To be advertised, debated, understood, and accepted

by all employees by all employees Plan to execute strategyPlan to execute strategy

– For launch of projects to implement the strategyFor launch of projects to implement the strategy– For carry-out of projects via execution actions, For carry-out of projects via execution actions,

monitoring, and controlmonitoring, and control– For evaluation of project success and strategy For evaluation of project success and strategy

performanceperformance

Engineering process – Engineering process – activity methods and activity methods and techniques (11)techniques (11) Enterprise competency engineering processEnterprise competency engineering process

1.1. Specify enterprise’s competency gaps, based on vision and Specify enterprise’s competency gaps, based on vision and strategy plans for product/servicestrategy plans for product/service

– Identify required new competenciesIdentify required new competencies

2.2. Conduct analysis for a technical approach to bridging the Conduct analysis for a technical approach to bridging the time-phased competency gapstime-phased competency gaps

– Identify a solution approach such as buying (licensing or Identify a solution approach such as buying (licensing or outsourcing), cultivating, and/or co-developing.outsourcing), cultivating, and/or co-developing.

3.3. Design a competency acquisition mapDesign a competency acquisition map– Develop a balanced portfolio of capabilitiesDevelop a balanced portfolio of capabilities– Create a resource and capability acquisition agendaCreate a resource and capability acquisition agenda

4.4. Develop an implementation plan for securing required Develop an implementation plan for securing required competenciescompetencies

– Develop a hiring & training plan for in-house resource Develop a hiring & training plan for in-house resource acquisitionacquisition

– Develop a competency qualification plan for external resource Develop a competency qualification plan for external resource acquisition acquisition

Engineering process – Engineering process – activity methods and activity methods and techniques (12)techniques (12) Enterprise capacity engineering processEnterprise capacity engineering process

1.1. Specify enterprise’s capacity gaps, based on vision, Specify enterprise’s capacity gaps, based on vision, strategy, and competency. strategy, and competency. – Identify required new capacityIdentify required new capacity

2.2. Conduct analysis for a technical approach to bridging the Conduct analysis for a technical approach to bridging the time-phased capacity gapstime-phased capacity gaps– Identify a solution approach such as buying (licensing or Identify a solution approach such as buying (licensing or

outsourcing), or cultivating a resource (a machine, a worker, or outsourcing), or cultivating a resource (a machine, a worker, or a computer system including an ERP system)a computer system including an ERP system)

3.3. Design a capacity acquisition/decommission mapDesign a capacity acquisition/decommission map– Develop a balanced portfolio of capacity requirementDevelop a balanced portfolio of capacity requirement– Create a resource acquisition/decommission agendaCreate a resource acquisition/decommission agenda

4.4. Develop an implementation plan for meeting time-phased Develop an implementation plan for meeting time-phased capacity requirementcapacity requirement– Develop a hiring & training plan for in-house human resourceDevelop a hiring & training plan for in-house human resource– Develop an acquisition plan for qualified external resourcesDevelop an acquisition plan for qualified external resources– Develop decommission plan for excessive resources Develop decommission plan for excessive resources

Engineering process – Engineering process – activity methods and activity methods and techniques (13)techniques (13) Enterprise structure engineering processEnterprise structure engineering process

1.1. Define enterprise system structural specifications, based on Define enterprise system structural specifications, based on vision strategy, competency, and capacity requirement for vision strategy, competency, and capacity requirement for product/serviceproduct/service

2.2. Conduct analysis for a technical approach to enterprise system Conduct analysis for a technical approach to enterprise system structuringstructuring– Decide on a conceptual solution such as a job shop vs. a cellular Decide on a conceptual solution such as a job shop vs. a cellular

shopshop– Furthermore, possible migrating from a job-shop structure to a Furthermore, possible migrating from a job-shop structure to a

cellular layout over time cellular layout over time

3.3. Design an enterprise system structureDesign an enterprise system structure– Enterprise structural design for physical, managerial, and computer Enterprise structural design for physical, managerial, and computer

systemssystems– Enterprise component design for the three system elementsEnterprise component design for the three system elements

Develop an implementation plan for enterprise system structureDevelop an implementation plan for enterprise system structure– Implementation plan for physical, managerial, and computer Implementation plan for physical, managerial, and computer

systems structuresystems structure– Implementation plan for physical, managerial, and computer Implementation plan for physical, managerial, and computer

systems component.systems component.

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T2-3: Engineering process