Grady J.O. System Synthesis: Product and Process Design

CRC Press, 2010 — 538 p. — ISBN: 978-1-4398-1962-3Unlike most engineers, system engineers focus on the knowledge base needed to develop good systems in a cross-functional fashion rather than in-depth on isolated topics. They are often said to be a mile wide and an inch deep in what they do know. System Synthesis: Product and Process Design provides insight into complex problems, focusing on the boundary conditions that exist between the knowledge domains of the specialized engineers populating a program and the product domains related to the product being developed by different teams on a program.
Based on the author's 45 years of experience, the book examines the three activities that must take place in the development of any system between the completion of the requirements work and the verification of work. The author delineates the role of the system engineer in design, material procurement, and manufacturing, clearly describing how to do key tasks such as trade studies and interface integration. He broadens the discussion of the system development process to include the whole space between requirements and verification work, covering product design, procurement, and manufacturing from a system engineer's perspective.
Filling the void often found in system engineering books relative to design, procurement, and manufacturing, this book explores integration work as it relates to the three synthesis activities. It discusses integration, optimization, and coordination of program, product, and process design, provides coverage that partitions all interfaces into three subsets, and covers how to manage and technically integrate each. The book defines the primary benefit system engineers bring to the party as their ability to perform integration work, optimizing the design process to achieve goals that others cannot envision.Acronyms
one: The fundamentals
one Introduction
Systems and their birth
Synthesis, optimization, and integration: What are they?
Toward a more effective process
Scope of integration workone: The fundamentals
two: Enterprise common process integration
three: Product system definition
four: Product design synthesis
five: Specialty engineering methods and models
six: Concurrent post-design process synthesis
seven: Closing
two System development process overview
The global situation
Top-down work sequence models
Traditional waterfall model
The V model
The spiral model
A common desire
Variations on a theme
Process definition
three The human basis for integration
Human limitations drive integration
The fundamental integration mechanism
Integration from a link perspective
The dark ages of system engineering
Order versus creativity
Mathematical chaos as an alternative
four Integration components, spaces, and cells
Setting the stage for integration decomposition
Integration components
Integration spaces
Integration cells
Program world line
Integration principles
Domain of the system engineer
This may be a little mad
five The key roles
Specialization run amuck
Functional managers
Program managers and team leaders
System engineers
Domain engineers
Top management
six Organizational structures
Updating matrix management
A model program organization structure
An alternative team structure
Resistance to IPPT
Human resistance
PPT-stimulated personnel staffing problems
Personnel evaluation problems
C/SCS criteria conflict
Model matrix for this book
The virtual team concept
Extension to large organizations
Lowest common team concept
A process-based organization
The organizational structure for the thoroughly modern person
seven Information systems and communications
The critical nature of communications
A common database
Program interim common database
The development information grid
The toolbox ring
Toolbox ring-to-DIG interface
The tool-to-tool interface
DIG content evolution to the final data repository
Common database approach
Web-based common data
Model-based development
War room or wall
Virtual teams in your future
Integration excellence = communications
Program interfaces
two: Enterprise common process integration
eight Enterprise process requirements definition
Process requirements sources
Enterprise structured analysis
The enterprise vision statement
Structured analysis of enterprise vision
Enterprise entity structure
Industry process standards
Standards as process requirements
System engineering standard
Software engineering standard
Coordination between internal and external standards
Enterprise process documentation
Knowledge base coordination with process responsibilities
Requirements union
nine Enterprise process design
Preamble
Process component
Responsibility component
Work responsibility fusion through allocation
Pull the strings
EIT efforts
Functional planning strings
All of the functions
The organizational RAS
The functional departments
String levels
Generic program preparation and continuous process improvement
Being prepared is better than not
Continuous process improvement using metrics
Generic preparation
Tuning our process to customer needs
Applicable documents analysis
Program audits by functional departments
Benchmarking
Where is your process description?
ten Integrated program planning
Goals
Traditional planning methods
The need statement
The system specification
The work breakdown structure dictionary
The statement of work
Work coding and detailed work planning
U.S. Air Force integrated management system
Introduction to the JOG system engineering planning model
Progressive planning granularity
Program plans
eleven Transition to implementation
Awaiting contract award
Generic identity
Program work definition
Work assignment and implementation
Functional management responsibilities
Populating the teams
Bringing in the resources
Facilities
Space improvements and team space allocation
Computing and communication
Firing up the program relationships
The customer
The procurement process
Associate relations
Winding down the beginning
three: Product system definition
twelve System modeling and requirements identificationOverviewDevelopment pattern overviews
The current system and hardware pattern
The current software pattern
System definition
Initial system architecting
Traditional structured analysis
Top-down software development
Integration at the gap
Tools integration in the near term
Next generation integrated development
The outputs
thirteen Product entity definition
Structured analysis
Product entity structure synthesis overview
Product entity block diagramming
Product entity overlays
WBS overlay
Configuration item overlay
Specification tree overlay
Manufacturing, procurement, and engineering breakdown structure overlays
PPT assignment
fourteen Interface definition
Interface analysis
Interface defined
The interface dilemma
The solution
n-Square diagramming methods
Schematic methods
Schematic symbols
Schematic symbols schematic discipline
Schematic symbols interface coding
Schematic symbols interface coding ultimate SBD
Schematic symbols interface coding ultimate SBD expansion
Schematic symbols interface coding ultimate SBD innerface expansion
Crossface expansion
Crossface compound expansion
Interface dictionary
Three views of interface
Interface responsibility models
Set theoretic view
Annotated schematic block diagram
The special need for external interface development
Degree of interface extension
A rationale in support of IPPT
fifteen Requirements integration
What is requirements integration?
Requirements integration responsibility
System level SRA overview
Requirements integration activities
Individual requirements audit
Traceability
Correctness of style
Understandability
Singleness of purpose
Quantification
Ierifiability
Good judgment and good sense
Requirements set attributes
Consistency
Completeness
Minimized
Uniqueness
Balance
Margin check
TPM status check
Specification format check
Engineering specialty integration overview
Interface requirements analysis integration
Environmental requirements analysis integration
Programmatic requirements integration
Hardware – software integration
Structured constraints deconfliction
Can there be too many requirements?
Deconfliction
four: Product design synthesis
sixteen Program execution
The central idea
Controlling the well-planned program
Program execution controls
Alas, good planning is not everything
Implementing the IMP/IMS
Controlling the advancing wave
Summing up
Discontinuity management
Discontinuity defined
Discontinuity detection
Cost and schedule triggers
Product performance trigger
Technology trigger
Risk assessment and abatement
Formal risk identification
Program replanning
seventeen Design modeling and simulation
What is a model?
How are models used in the synthesis work?
Use of models and simulations
Math models
Physical models
Prototypes and pilot models
Descriptive models
Executable models
Representation configuration control
eighteen Product design decision-making
Concept development
The requirements
The bridge between problem and solution
Preferred solution selection
Trade fundamentals
Trade requirements
Our value system
Identifying candidates
Candidate development
Candidate values
Trade study matrix models
Simple entries
Pugh concept selection approach
Technometric trade study approach
Objective trade study approach
Trade study or design concept review
Post-concept action
Concept documentation
Configuration management of trade results
nineteen Product design integration in an IPPT environment
What is the principal problem?
How do we accomplish crossface integration?
There are more interfaces
System optimization
Other PIT actions during design
Special hardware – software integration needs
twenty Preliminary design
The purpose of preliminary design
Requirements validation, risk identification, and risk mitigation
Design ideas capture and baseline control
Design communication
Independent work
Continuous meeting
Cyclical work and meetings
Preliminary design review
twenty-one Detailed design
Information and communication importance
Integrated team activity
Specialty engineering relations
Configuration control
Representations control
Continuing specifications maintenance
Product design control
Technical control of hardware sources
Internal teams
Design to specification procurement
Manufacture to print procurement
Commercial off the shelf
s, materials, and processes
Sister division sources
Software design
Critical design review
twenty-two Integration of test and analysis results
Two Vs for victory
Configuration control
&V article control matrix
Test integration
Non-test integration
five: Specialty engineering methods and models
twenty-three Introduction to specialty engineering and concurrent engineering
Specialty fundamentals
Systems and their development
The knowledge foundation
Enter the specialty disciplines
Several kinds of specialists
Every engineer
The system analyst
The specialty engineer
The past
The future
A generic specialty engineering process
Concurrent development and IPPT overview
The concurrent engineering bond
Team formation
Specialty engineering in requirements analysis
Parent team requirements development
Child team requirements development
Specialty engineering requirements identification responsibility aid
Requirements capture
Requirements integration
Specialty constraints communication
Checklist approach
Individual person-to-person
Organized interaction meetings
Specialty engineering in design
Concurrent preliminary design development
Concurrent detailed design development
Decision support
Specialty design assessment
Noncompliance identification
Noncompliance correction
Engineering specialty activities
twenty-four Reliability
Reliability overview
Reliability modeling and allocation
Failure modes effects and criticality analysis
Reliability analysis and prediction
Other design support functions
Reliability verification
Field reliability data
twenty-five Maintainability
Maintainability overview
Maintainability modeling and allocation
Maintainability analysis and prediction
Maintainability verification
twenty-six Availability and RAM integration
Availability overview
Availability measures
Inherent availability
Achieved availability
Operational availability
Availability integrity
Availability verification
twenty-seven Logistics engineering
Supportability and integrated logistics support
Maintenance engineering
Spares
Personnel and training
Technical data
Testability, integrated diagnostics, and built-in test
Support equipment
Transportability, mobility, and portability
Packaging and shipping
twenty-eight Safety, human engineering, security, and environmental impact
System safety and health hazards
Hazard analysis and reporting
Human engineering
System security
Environmental impact
twenty-nine Parts, materials, and processes engineering
PMP engineering overview
s engineering
Materials engineering
Process engineering
Contamination control
Application to software
thirty Other specialty disciplines
How many can there be?
Survivability and vulnerability
Electromagnetic compatibility
Radio frequency spectrum management
Electrostatic discharge
Producibility
Operability
Design to cost and life cycle cost
Value engineering
Operations research or analysis
Other specialty engineering disciplines
thirty-one System analysis disciplines
Specialty engineering differences
Mass properties
Space engineering and packaging
Guidance analysis
Structural dynamics and stress analysis
Aerodynamics
Thermodynamics and thermal analysis
Anything missing?
six: Concurrent and post-design process synthesis
thirty-two Procurement and material integration
Customer choices
Procurement as an early team member
Purchasing modes
Buy to specification
Buy to drawings
Buy off the shelf
Procurement cycle need for engineering support
Contract help
Source selection and contract award
Monitoring the supplier
What is so different about suppliers?
thirty-three Manufacturing process design and integration
Process overview
Process definition
Manufacturing instructions development
Kitting material development
Tooling
Personnel and training
Facilities
Integrated product development during production
thirty-four Quality influences
What is quality?
Product quality components
Product quality
Process quality
thirty-five Post development
System employment overview
Operational test and evaluation
Initial operational capability
Operations and maintenance
Logistics support
Fielded system modification
Disposal and possible rebirth
Integration during system phaseout
seven: Closing
thirty-six Closing
Integration at the beginning
Process improvement
The current cutting-edge
Universal modeling set for system architecting
Model-driven development
System development in a broader context
Integration at the end