1. Project Management Jan 27, 2006 James R. Matt Technical Fellow General Motors Corp

2. “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

3. Key Thoughts & Simple Tools

4. Coarse to Fine Product Development Needs & Ideas Organize & Prioritize Select Proof of Concept Technical Solution Development Production Readiness Manufacturing & Production Customer and Market Feedback (data from: Marketing, Sales, Quality, Benchmarking, Customers)

5. Spider Chart Performance Targets and Key Wins Today’s Product or Situation Best in Class Competition Targets for new Design Key Wins Faster Speed Smaller Size Durability Life

6. Trade-off study matrix Design Option #1 Design Option #2 Design Option #3 Example Criteria Performance Cost Mass Quality Volume / Size Risk Durability Summation Key: “ ++ ” = Much Better “ + ” = Somewhat Better “ 0 ” = No Improvement “ - ” = Worse “ - - ”= Much Worse

7. Trade-off study matrix Design Option #1 Design Option #2 Design Option #3 Example 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

8. Engineering Project Management

9. Phase 00 Define Requirements, Key Interfaces, & Constraints Concepts Generate Detail Concept Product Development Approve Project Plan, Team, and & Deliverables Requirements Agreement Select & Approve Design Concept 12 Approve Detail Concept 43 Optimize & Verify Approve Concept Verification 5 Technology Planning Determine Needs, Select Projects. & Assign Teams I- Identify D 1 Define Requirements D 2 – Design Concept O- Optimize V- Verify DFSS ‘ IDDOV& Product Development Design for Six Sigma IDDOV

10. Phase 00 Define Requirements, Key Interfaces, & Constraints Product Development Approve Project Plan, Team, and & Deliverables 12 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 to determine Requirements Conduct Gate Review #1 Tasks: Generate & Assess Alternative concepts Perform Evaluations Concept Tradeoff Study Refine Specifications & RobustEng Plan (DOE) Conduct Concept Review and Approve Design Concept Tasks: Develop purchasing info Conduct Robust assessment Optimize Concepts Conduct Peer Review Update all Business, Technical, and Project Documents Approve Details Concept Make Purchasing Decisions Tasks: Develop Design Finalize Development &Test Plan Construct, Build, and Test Prototype Verify Hardware, Software to Technical Requirements Conduct Final Design Review Update all Business & Technical Documents Define Requirements Key Interfaces & Constraints Concept Generation & Design Selection Robust Assessment & Purchasing Optimize & Validate Define Initial Project Requirements Agreement Select & Approve Design Concept Approve Detail Concept Approve Concept Verification Concepts Generate Detail Concept Optimize & Verify

11. 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.

12. Risk

13. ‘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) Method 1.Brainstorm Potential Problems 2.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

14. Pareto Diagram RPN (Risk Priority Number) 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

15. Modularity & Standard Parts as Risk Reduction

16. Component Design & Build Approach Transfer Function Input Intended Output Risk: Output not Design Intent

17. Component Design & Build Approach Transfer Function Input Intended Output Risk: Unintended Interactions Transfer Function Input

18. Independent Component Design & Build Approach

19. Component Design & Build Approach

20. Modular Build Approach Sub-assembled & Pre-Tested Modules

21. Modular Build Approach with Standard Parts Using Standard Parts

22. Example Headlamp & Turn Signal Multifunction Electrical Switch

23. 5 Phase Problem Resolution 1.Problem Definition 2.Containment, Immediate Corrective Action 3.Root Cause 4.Irreversible Corrective Action 5.Verification

24. Example Multifunction Headlamp Switch Headlamp On / Off Headlamp High / Low Turn Signal Cruise Control Set, 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

25. Headlamp On / Off Headlamp High / Low Turn Signal Cruise Control Set, On, Off CustomerElectrical Control However: Mechanical Interaction Inside the Multifunction 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 Example Multifunction Headlamp Switch

26. DOE factors for test matrix 1) Type of Lubricant in the switch 2) Contact Material 3) Contact Plating 4) Spring Pressure The optimal combination was found and the design was quickly changed. No field issues were found

27. Example Upper Strut Mount Design For Six Sigma Example

29. 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

30. Consider Classis Failure Mechanism that Cause Failure Modes Creep Fracture Yield Physio-Chemical Instability Dimensional Incompatibility Contamination Vibration and Mechanical Shock Environmental Wear

31. 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)

32. Matrix Functions vs Failure Mechanisms – Evaluate Risk due to Sensitivities React Position Isolate Filter Rotate Limit Amplify Functions Failure Mechanisms

33. Matrix Functions vs Failure Mechanisms – Evaluate Risk due to Sensitivities React Position Isolate Filter Rotate Limit Amplify High Med

34. Matrix Assessment – Knowledge Gathering

35. 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 Contamination Yield Fatigue Fracture Vibration / Mechanical Shock Wear Electrical / Software Compatibility Physio-Chemical Instability Creep Dimensional Incompatibility DFSS - Front Upper Strut Mount Noise Factors Functions: Position, Isolate, React Loads Energy Desired Functional Characteristic

36. Noise Factors Functions: Position, Isolate, React Loads Energy Primary Function The Forward Pass Position Isolate React Loads Failure Mechanisms Environment Contamination Yield Fracture Vibration / Mechanical Shock Wear Electrical / Software Physio-Chemical Instability Creep Dimensional Incompatibility Primary Functions Likelihood: of compromise of a “Primary Function” due to a Sensitivity to “Failure Mechanism”. Strong Likelihood = “ + ” Neutral = “ 0 ” Not Sensitive = “ – ”

37. Functions: Position, Isolate, React Loads Anticipated or Historic Problems The Reverse Pass learn for what has happened before

38. Noise Factors Chart the probability of each Failure Mechanism contributing to historic problems and loss of desired Functions Failure Mechanisms Environment Contamination Yield Fracture Vibration / Mechanical Shock Wear Electrical / Software Physio-Chemical Instability Creep 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 Energy Desired Functional Characteristic Anticipated Problems Forward Pass Reverse Pass

39. Now think in terms of the design Components (and for competing design options) A – Inner Metal B – Primary/Shear Isolator C – Upper Rate Washer D – Reaction Washer E – Reaction Isolator F – Outer/Compression Isolator G – Main Stamping H – Lower Rate Washer A B C D E F G H

40. Top Mount Bearing

41. 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 Wear Physio-Chemical Instability Dimensional Incompatibility Position Isolate React Loads Noise at the end of life Loss of attachment Bearing Drag Non-linear road feel X X X X X X

42. 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

43. Idea Generation Do 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. Execution Set 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

44. Closing Thoughts Good Luck Get Started Have Fun & Expect Things to go Wrong