esd.36 l3 dsmtaskbaseddspace.mit.edu/.../80702/esd-36j-fall-2003/...task.pdf11 sep 03 - esd.36j spm...
TRANSCRIPT
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11 Sept 03
ESD.36J System & Project Management
Instructor(s)
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- Tasked-Based DSMs
Prof. Olivier de Weck
Lecture 3
Based mainly on materials by Prof. Steve Eppinger, © 2003
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- ESD.36J SPM11 Sep 03 2
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- Today’s Topic
DSM IntroductionProject Graphs --> Task-based DSMsDSM Operations
sequencingpartitioningtearing
DSM Tools and References
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- ESD.36J SPM11 Sep 03 3
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- Lessons Learned from CPM/PERT
+Focuses attention on a subset of critical tasksDetermine effect of shortening/lengthening tasksEvaluate costs of a ”crash” programLinks task durations to schedule
-Doesn’t capture task iterations, in fact …Prohibits iterations = called “cycle error”
However, iterations are one of the essentialfeatures of design and development projects
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- ESD.36J SPM11 Sep 03 4
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- PERT and CPM Charts4 2
Start 3
6
Finish
8
5
4
days
activity precedence
critical path
activity and durationSimple network diagrams are easy to understand.We cannot represent the coupled/iterative task relationships.
prohibited
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- ESD.36J SPM11 Sep 03 5
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- Sequencing Tasks in Projects
Three Possible Sequences for Two Tasks
A B
A
B
A
B
Dependent(Series)
Independent(Parallel)
Interdependent(Coupled)
Discussed so far New !
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- ESD.36J SPM11 Sep 03 6
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- Interdependent TasksSometimes iterative tasks are referred to as “chicken-and-egg” problems in designExample from Spacecraft Design
Inertia and Attitude Control Coupling
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+EGGS
CHICKENS
© Lyneis
Define s/csize, massinertia matrix
Size reactionwheel assembly(RWA) torqueand momentumcapacityAdds mass
inertia, ca. 50kg/wheel Reaction
Wheel Assembly
Nexus Spacecraft S/C total mass,total inertia:800kg, 3000 kgm2
External DisturbancesSlew Rate RequirementDesaturation Interval
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- ESD.36J SPM11 Sep 03 7
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- Experiences and QuestionsExamples from your own design experience ?…Questions that arise:
How can iterations be represented?How do you enter the loop?
What are the going-in assumptions?
When do you exit the loop?When has design convergence been achieved?How many iterations are needed?
How do the iterations impact…Project schedule and cost?Product/Design quality?
How can iterations be planned strategically? PDP design = “meta-design”
today
nextlecture
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- ESD.36J SPM11 Sep 03 8
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- What is a DSM?Potential answer to first question:
How can iterations be represented?
Design Structure Matrix (DSM)A two-dimensional matrix representation of the structural or functional interrelationships of objects, tasks or teams
SynonymsDesign Structure Matrix (DSM)N2-Diagram (“N-squared”)Dependency Structure Matrixothers …
Types of DSMsObject-based, Task-based, Team-based
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- ESD.36J SPM11 Sep 03 10
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- Task-Based DSMs
A,0
B,10 D,30
C,20 E,20 F,40
G,20 H,0
Start
Finish
0 10
0 20
20 50
20 40 40 80
80 100
A B C D E F G HABCDEFGH
010
2030
2040
200
task
Project Graph
DSM
inputsinto task
( upstream)
inputsinto task
(downstream)
outputsfrom task( upstream)
translate
outputsfrom task ( downstream)
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- ESD.36J SPM11 Sep 03 11
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- Team-Based DSMs
Team 1
Integration Team
Team 2
Team 4
Team 3
Flywheel Connecting Rods
Crankshaft
Cylinder HeadsIntake Manifold
E.V.A.P. Fuel System Air Cleaner
Throttle Body
Electronic Control Module
PistonsEngine BlockLubrication
Water Pump/Cooling
Camshaft/Valve Train
ExhaustE.G.R.
A.I.R.
Electrical System Ignition Engine Assembly
Accessory Drive
GMEngine
DevelopmentTeam
© Eppinger
F G E D I A C B K J P N Q R B K O L M H S T U VCrankshaft F F • • • • • • • • • • • •
Flywheel G • G • • • •Connecting Rods E • E • • • • • •
Pistons D • • • D • • • • • • • • •Lubrication I • • • • I • • • • • • • • •
Engine Block A • • • • • A • • • • • • • • • •Camshaft/Valve Train C • • • • C • • • • • •
Cylinder Heads B1 • • • • • B1 • • • • • •Intake Manifold K1 • • • • K1 • • • • •
Water Pump/Cooling J • • • • • • J • • • • • • • • •Fuel System P • P • • • • • • • • • •Air Cleaner N • N • • • • • •
Throttle Body Q • • • Q • • • • • • • • •EVAP R • • R • • •
Cylinder Heads B2 • • • B2 • • • • • • • •Intake Manifold K2 • • • • • • K2 • • • • • • •
A.I.R. O • • • • • • O • • • • • •Exhaust L • • • • • • • • L • • • • • •
E.G.R. M • • • • • • • • M • • • • •Accessory Drive H • • • • • • • • • • • • • • • • H • • • •
Ignition S • • • • • • • • • • • • • • • • S • • •E.C.M. T • • • • • • • • • • • • • • • • • • T • •
Electrical System U • • • • • • • • • • • • • • • • • • • U •Engine Assembly V • • • • • • • • • • • • • • • • • • • • • • V
Frequency of PDT Interactions
• Daily • Weekly • Monthly
Team 1
Team 2
Team 3
Team 4
Integration Team
Map IPT teamstructure to DSMvia frequency ofinteraction- daily, weekly, monthly
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- ESD.36J SPM11 Sep 03 12
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-The Design Structure Matrix:An Information Exchange Model
Donald V. Steward, Aug. 1981IEEE Trans. on Eng'g Mgmt.
Interpretation:Task D requires information from tasks E, F, and L.Task B transfers information to tasks C, F, G, J, and K.
Note:Information flows are easier to capture than work flows.Inputs are easier to capture than outputs.
CD
AB
GH
EF
KL
IJ
C DA B G HE F K LI J•
••
••
••
••
••
•
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- ESD.36J SPM11 Sep 03 13
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The Design Structure Matrix (Partitioned, or Sequenced)
TaskSequence
Note:Coupled tasks can be identified uniquely. The display of the matrix can be manipulated to emphasize certain features of the process flow.
C
D
A
B
GH
E
F
KL
I
J
C DAB GHEFK L IJ
Sequential
Parallel
Coupled
••
••
••
••
••
••
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- ESD.36J SPM11 Sep 03 14
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- Tearing Marks in the DSM
C
D
A
B
GH
E
F
KL
I
J
C DAB GHEFK L IJ
Series
Parallel
Coupled
••
••
••
••
••
••
Tear This Mark C
D
A
B
GH
E
F
KL
I
J
C DAB GHEFK L IJ
Series
Parallel
Coupled
••
••
••
••
••
••
Control
Tear the marks which break the coupled block into smaller ones or make it sequential.
Torn marks may becomeAssumptionsFeedbacksControls for the process
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- ESD.36J SPM11 Sep 03 15
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- DSM Sequencing ExerciseA B C D E F G H I J
A A X X X AB X B X X X BC C CD D X X X DE X E X EF X X X X F X FG X G X GH X X H X HI X X X I IJ X X J J
A B C D E F G H I JExcelMacro
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- ESD.36J SPM11 Sep 03 16
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Concurrent Engineering in the Small
Projects are executed by a cross-disciplinary team (5 to 20 people).Teams feature high-bandwidth technical communication.Tradeoffs are resolved by mutual understanding.“Design and production” issues are considered simultaneously.
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- ESD.36J SPM11 Sep 03 17
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Concurrent Engineering in the Large
Large projects are organized as a network of teams (100 to 1000 people).Large projects are decomposed into many smaller projects.Large projects may involve development activities dispersed over multiple sites.The essential challenge is to integrate the separate pieces into a system solution.The needs for integration depend upon the technical interactions among the sub-problems.
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- ESD.36J SPM11 Sep 03 18
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Semiconductor Development Example1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
1 Set customer target • x x •2 Estimate sales volumes x • x x •3 Establish pricing direction x • x •4 Schedule project timeline • x5 Development methods x • x x x x6 Macro targets/constraints x x • x x x x7 Financial analysis x x x x x •8 Develop program map x • x9 Create initial QFD matrix x x x x •
10 Set technical requirements x x x x • x11 Write customer specification x x x x x • O O O O O O O O12 High-level modeling x x x x • x x x13 Write target specification x x x x x x x x x • x x14 Develop test plan x x x x x • x15 Develop validation plan x x x x • 16 Build base prototype x x x x x x •17 Functional modeling x x x x x • x x x x x x x x O O O O O O O O O O18 Develop product modules x x x x x x x x x • O19 Lay out integration x x x x x x x x x •20 Integration modeling x x x x x x x • x x x21 Random testing x x • x x x22 Develop test parameters x x x x x x x • x x x23 Finalize schematics x x x x x • x x O O O O O24 Validation simulation x x x x x x x • x x25 Reliability modeling x x x x x • x26 Complete product layout x x x x x • x x27 Continuity verification x x x x x x •28 Design rule check x x x •29 Design package x x x x x • O O O O O O O30 Generate masks x x x x • x O31 Verify masks in fab x x x •32 Run wafers x • x O33 Sort wafers x •34 Create test programs x •35 Debug products x x x x x • O O O O O O O36 Package products x x x •37 Functionality testing x x x •38 Send samples to customers x x x x •39 Feedback from customers x •40 Verify sample functionality x •41 Approve packaged products x x x x •42 Environmental validation x x x x •43 Complete product validation x x x x x •44 Develop tech. publications x x • x x45 Develop service courses x x • x46 Determine marketing name x x x x x • x47 Licensing strategy x x x •48 Create demonstration x x x x x x •49 Confirm quality goals x x x x x •50 Life testing x x x • x x51 Infant mortality testing x x x x • x52 Mfg. process stabilization x x x • O O53 Develop field support plan x x •54 Thermal testing x x x •55 Confirm process standards x • x x56 Confirm package standards x x x x x • x57 Final certification x x x x x x x x x x x •58 Volume production x x x • x59 Prepare distribution network x x x x x x x x •60 Deliver product to customers x x x x x x x x x •
x = Information Flows = Planned Iterations O = Unplanned Iterations • = Generational Learning
Concurrent Activity Blocks
Potential Iterations
Generational Learning
Sequential Activities
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- ESD.36J SPM11 Sep 03 19
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-How to Create a Task-Based Design Structure Matrix Model
Select a process or sub-process to model.Identify the tasks of the process, who is responsible for each one, and the outputs created by each task.Lay out the square matrix with the tasks in the order they are nominally executed.Ask the process experts what inputs are used for each task.Insert marks representing the information inputs to each task.Optional: Analyze the DSM model by re-sequencing the tasks to suggest a new process.Draw solid boxes around the coupled tasks representing the planned iterations.Draw dashed boxes around groups of parallel (uncoupled) tasks.Highlight the unplanned iterations.
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- ESD.36J SPM11 Sep 03 21
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-Mathematical Partitioning
1 2 3
2 5
1 4 5 3
5 2
2 5 2 4 2
2 2 03 9 0
10 09 3 7 0
9 0
x x xx xx x x xx xx x x x x
− + =
+ − =− − + =− + =
− + − =
E1
E2
E3
E4
E5
-5 variables-5 independent equations-no degrees of freedom
Occurrence Matrix Irreducible Subsets
1. Solve x2,x5 from E2 and E42. Solve x4 from E53. Solve x1 and x3 from E3 and E1
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- ESD.36J SPM11 Sep 03 24
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- Problematics DSM Software
Download the latest version of the PSM32 program at:
http://www.problematics.com30 day free trial version40 tasks maximum
http://www.problematics.com/
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- ESD.36J SPM11 Sep 03 25
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- Brake-System Design Process
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- ESD.36J SPM11 Sep 03 26
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- PSM32 Functionality
PartitioningDetect sequential, parallel and iterative task (blocks)
Ordering/SequencingTearing
Analyze block structureBreak big blocks into smaller blocks - torn mark becomes an assumption in the design processDetermine number of iterations to converge
SchedulingDevelop schedule and critical path (given task durations)
PSM32= “DSM Analyzer and Manipulator”
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- ESD.36J SPM11 Sep 03 27
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- PSM32 Toolbar : Summary
Exit
Create new project
Open a project
Print Insert a row Zoom (percentage)
Move down diagonally
Help
Info/Options Delete a row Zoom in Reset Matrix
Find Move row down
Mark notes Move up diagonally Tear
Save Move row up
Edit row Zoom out Partition
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- ESD.36J SPM11 Sep 03 28
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- Partitioning
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- ESD.36J SPM11 Sep 03 29
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- Identifying the Mark to Tear
Tear (assume) this information
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- ESD.36J SPM11 Sep 03 30
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Separation of Kinematics from Thermodynamics
Kinematics (Stopping the Car)
Thermodynamics (Cooling the Brakes)
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- ESD.36J SPM11 Sep 03 31
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- What’ really different?“In a critical path schedule this simultaneous or iterative situation does not arise or is not explicitly shown because one is dealing only with items to be done. But here we are dealing both with what is to be done and what information is to be determined. Information is needed to determine how a task item it to be done, and information is produced by doing the task. The introduction of information flowraises the possibility, indeed the probability, of being confronted with blocks of more than one item where each item in the block depends on all the other items in the same block. This is usually resolved by making assumptions and iterating to refine the assumptions.”
D. Steward
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- ESD.36J SPM11 Sep 03 32
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- ConclusionsIterations are an essential part of design
Some iterations are desirableimprove quality
Some iterations are undesirable (rework)can cause delay and cost increases
Differences between CPM/PERT and DSMCPM/PERT is work-flow oriented
time and schedule flowuseful for planning and tracking detailed execution of project
DSM is information-flow orientedDSM captures iterationsDSM shows blocks , i.e. the macro-tasksuseful for analyzing and improving design processes
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