scott potter - 1 date? extending cmmi to hardware engineering disciplines 2003 ndia systems...
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Assured Communications Scott Potter - 1Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Extending CMMI to Hardware Engineering Disciplines
NDIA System Engineering Conference
October 2003
Scott Potter
Harris Corporation
Govt. Communications Systems Division
Digital Technology and Network Systems
Assured Communications Scott Potter - 2Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Introduction
• Extending CMMI to Hardware Engineering Disciplines– Application context– Process improvement infrastructure– Hardware process improvement objectives– Improvement approach– Metrics– Lessons Learned– Summary
Assured Communications Scott Potter - 3Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Application Context
OPTICAL PROCESSING
PRECISION ROBOTICS
ADVANCED SIGNAL PROCESSING
SYSTEM DEVELOPMENT & INTEGRATION
LOW POWER / MICRO-ELECTRONICS
SYSTEM COMMAND & CONTROL
SPECIALIZED ANTENNAS
LEADING EDGE TECHNOLOGIES MISSION KNOWLEDGE
•C4I Systems
•Signal Intercept & Processing
•Exfiltration
•Remote Operations
Assured Communications Scott Potter - 4Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Engineering Process Improvement
Engineering Process Council (EPC)
Engineering Process Group (EPG)
Engineering VP,Program Area VPs,EIT Director
EPG Leader,EPG Staff,Discipline Leads
EngineeringManagers,Staff
Tools, Methods, andTechnology (TMTs)
ActionTeams
Executive Steering Group
Coordinate and ManageCross-disciplinary Action Teams
Systems EngineeringSoftware EngineeringElectrical EngineeringMechanical EngineeringAntennas / RF / OpticsIntegration & Test EngineeringSpecialty / Support EngineeringEngineering Information TechnologyShort-Term Tasks Long-Term, Persistent
DisciplineTeams (8)
Assured Communications Scott Potter - 5Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
CMMI Process Areas Staged
Organizational Innovation and DeploymentCausal Analysis and Resolution5 Optimizing
4 Quantitatively Managed
3 Defined
2 Managed
ContinuousProcess Improvement
QuantitativeManagement
ProcessStandardization
BasicProjectManagement
Organizational Process PerformanceQuantitative Project Management
Requirements DevelopmentTechnical SolutionProduct IntegrationVerificationValidationOrganizational Process FocusOrganizational Process DefinitionOrganizational Training Integrated Project ManagementRisk ManagementDecision Analysis and Resolution
Requirements Management Project PlanningProject Monitoring and ControlSupplier Agreement ManagementMeasurement and AnalysisProcess and Product Quality AssuranceConfiguration Management
QualityProductivity
RiskRework
1 Initial
Process Areas (PAs)Maturity Level Focus
Assured Communications Scott Potter - 6Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware CMMI Action Plan
Project SE/SW/HW CMMI Mini-Assessments, QA audits
HW CMMI Mini-
Assessment
Process Updates
HW CMMI Mini-
Assessment
Process and Training Updates
Deploy HW CMMI Process Updates, Training, and Institutionalization
• Action teams• Command media
• Command media• Training updates• CMMI delta training
…
…
CompletedIn-ProgressPending
• Command media gaps• Judge institutionalization
• Delta mini-assessment
SE/SW Process Deployment, Training, Assessments, and Improvement
HW Command
Media
HW Metrics Deployment
• Baseline (pre-CMMI)• Integrated EPG CCB
• Integrated metrics tool (SE, SW, HW)
Assured Communications Scott Potter - 7Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Engineering Development Process
Division Standard Engineering Process
ProjectDefined
Processes
• SEMP• SDP• EDP• MDP• Other plans
• Manuals
• Handbooks (inter-disciplinary processes)• Training (process and technical)
• Policies
Assured Communications Scott Potter - 8Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Electrical Engineering Process Overview
BUSINESSACQUISITIONPHASE
QUALIFICATION • Business Development• Systems Engineering Support
PURSUIT • Preliminary Requirement• Preliminary HW architecture
PRE-RFPDEVELOPMENT
• Functional Analysis & Trades• Baseline Design Review• Cost Boundaries
PROPOSAL • HW Architecture & Electrical Requirements Definition
• Functional Analysis & Trades• Cost & Schedule Estimation• Write Preliminary EDP
POST-PROPOSAL • Systems Engineering Support
ACTIVITIES
PRODUCTS
• Preliminary Electrical Development Plan (EDP)• Proposal• White Paper• Design Documentation (not part of proposal)• Initiate Certification Activity
MILESTONES AWARD
Proposal Baseline
SYSTEMREQUIREMENTS
• Technical Management and Planning
• System Engineering Support– Requirements B1’s Draft– Mission Analysis– Functional Analysis– Performance Analysis– Verification Analysis
SRR
Requirements Baseline
• EDP Updated• Design Documentation
SYSTEMDESIGN
• Technical Management and Planning
• Support Initial Hardware Tree w/CML Structure
• System Engineering Support• System Synthesis
– Architecture Design– Requirements Allocation– Performance Analysis– Risk Analysis– Test Planning
SDR
Functional Baseline
• CI Spec• EDP• ICDs• Design Documentation (TM)
FABRICATION/CODE/
INTEGRATION
• Technical Management and Planning
• Fab & Assemble CIs• CI Verification Preparation• CI Test• CI Acceptance• Update Documentation• Support System Integration & Test
• CI Test Procedures• ECOs• Configuration
TRR
VERIFICATION
• Support Test Engineering• Support PCA/FCA• Support FQT
SYSTEMTEST
• Documentation Updated
PRODUCTION
PRR
PRELIMINARYDESIGN
PDR
Allocated Baseline
• Technical Management and Planning• CI Definition
– Functional Allocation– Internal Interface Definition– Performance Analysis– Verification Analysis
• Generate Preliminary CI Test Plan• Review Preliminary Design (PDR)
• Block Diagrams• Long Lead Material Ordered• Design Documentation• Preliminary CI Test Plan• PDR Package
SSR
DETAILEDDESIGN
CDR
Design Baseline
• Technical Management and Planning• CI Design
• Functional Allocation• Internal Interface Design• Performance Analysis• Verification Analysis
• Documentation Generation• Drawings• Specifications (PIDS)
• Final CI Test Plan• Critical Design Review (CDR)
• Released & Controlled Set of Documentation
• Material Ordered• CI Test Plan• Preliminary CI Test Procedure• CDR Package
SYSTEMTEST
FIELDSUPPORT
• Support Installation• Support the electrical portions of
the development of a training program
• Technical Support• Support SAT
BASELINES
• Assist in Production Planning• Assist in Production Test• Assist in Electrical System Debug• Support Certification Activity
Electrical Engineering Process Overview
TechnicalBaselineReview
EngineeringCost
Review
Job Start Up Review
Product Baseline
• EE manual – process flow diagram– Integrated command media across all
engineering disciplines– Standard life cycle phases– Activities, products, milestones,
baselines– Sub-process / Interfaces with SE– Checklists and design/peer reviews
based on SE-based process
Assured Communications Scott Potter - 9Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Improvement Objectives
• Competitive bids– Productivity metrics– Labor metrics
• Predictive metrics– Predictable performance vs. plan
• Technological Capabilities– State of the art technology
• Innovative project applications• Attract and retain creative talent
These objectives drive how we plan and manage
Assured Communications Scott Potter - 10Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Improvement Projects
• HW Tools, Methodology, and Technology (TMT) initiatives – Special projects (lessons learned)– Standardization of work products– Design archive (cost history)– Metrics database
• Benchmarking; tool evaluations; process reviews• Technology roadmaps;
• Digital Engineering Technology areas (TMTs):• ASIC/FPGA (advance semiconductors)• Microsystems (microelectronics, MEMs, optics)• Network systems• Signal processing
• Metrics• Productivity• Qualitative information on designs (e.g. PWB metrics)
– Circuit card archive
Assured Communications Scott Potter - 11Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Metrics
• Metrics are collected, analyzed, and used to track project hardware engineering progress, performance, and quality– Process characterization– Predictive metrics– Historical performance
• Productivity• Cycle time
– Technical performance (capability, TPMs)• Timing, sizing, link budgets, etc.• Emphasis varies by program and application
– Engineering Cost Metrics Database (timecard charges)
Assured Communications Scott Potter - 12Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Historical Metrics
CircuitCard
Archive
PWBDatabase
ASIC/FPGADatabase
• Design status• Fabrication status• Approved vendors• Standard forms, templates
Used to track supply chain. Buyer, designer, QA, fabricator, and purchasing to electronically share, communicate, and track status
Fabricator
Management• Status• Metrics• Progress
Database of circuit cards• By program• Card count and description• Design summary / structure• Links to existing cards, SEER-H• Defines work codes for metrics• Reuse characteristics
SEER-HEstimating model
and metrics
Assured Communications Scott Potter - 13Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Hardware Estimating Process
Requirements
• Block Diagram• Material List• Travel, ODC• Subcontracts• Capital & Facilities• Design Process Map
BOEForms
Create ABottom-Up Estimate
Qualify The Bottom-Up Estimate
Review Forms WithEngineering Manager
Proposal Cost ReviewSummary Form(s)
RequirementsDocument
Establish The Requirements
WBS & ProgramSchedule
Proposal Cost ReviewSummaryH-2472
BOEForms
Complete The BOE Form and Generatethe Proposal Cost Review Summary
Create a bid for each WBS element
(Include costs from financial administrator)
• Metrics
• Design Archive
• Program Cost History
ConceptualDesignReview
Proposal CostReview
DesignTo Cost
met?
NO
YES
Define the Scope of Work
Compare against• similar-to design• productivity metric• parametric tool as appropriate
Assured Communications Scott Potter - 14Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
<ExampleProject>Proprietary Information – For Internal Division Use OnlyReporting Period: September 1999 PEM v3.0
Electrical Engineering Performance
Electrical Engineering Pins Issues/Actions
"Pins" issues/actions
Electrical Engineering Gates Issues/Actions
"Gates" issues/actions
Assured Communications Scott Potter - 15Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Trending - PWB Cycle Time
11
5
65.5
4
6.3 6.4
4.7
3.6
3
4.5 4.7
87.7
6
11.3
7.8
5
14
12
7.8
9.5 9.6
0
2
4
6
8
10
12
14
16
96Q4 97Q1 97Q2 97Q4 98Q1 98Q2 98Q4 99Q1 99Q2 99Q3 00Q4 01Q1 01Q2 01Q3 01Q4 02Q1 02Q2 02Q3 02Q4 03Q1 03Q2 03Q3 03Q4
Average Calendar Weeks Per PWB
Assured Communications Scott Potter - 16Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Trending - PWB Quality
Percent Of PWBs Error-Free
88%
83%
94%
98%
96%
91%
96%
92%
96% 96%
98%
95%94%
98%100%100%100%100%
98% 98%100%100%100%
70%
75%
80%
85%
90%
95%
100%
Assured Communications Scott Potter - 17Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Trending - PWB Defects Per Design
Number of ECOs and SIRs Per Design
0.09 0.11
0.29
0.55
1.00
0.74
0.03
0.130.1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
FY98 FY99 FY00 FY01 FY02 FY03
SIRs ECOs SIR Goal
Assured Communications Scott Potter - 18Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Training
• Customized employee training based on assigned role and gap analysis
• All PCB designers are IPC-certified• Process training (design of circuit cards, FPGAs, MCMs,
PWBs)• Web-based tutorial• New hire orientation
Assured Communications Scott Potter - 19Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Quality Assurance
• Process compliance and product quality is assured by Engineering Management oversight and quality audits– Periodic audits of PWB vendors– Supplier summits– Defect metrics– Change requests
Assured Communications Scott Potter - 20Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Lessons Learned
• Start a CMMI improvement project with a baseline assessment– Understand the model– Identify gaps– Implement the actions
• Ensure representation across projects and disciplines• Metrics help define, characterize, and improve processes
– Identify the prioritized areas for improvement– Start small, look for value– Use available data first before creating something new
Assured Communications Scott Potter - 21Date?
Extending CMMI to Hardware Engineering Disciplines2003 NDIA Systems Engineering Conference
Scott PotterHarris Corporation GCSDDigital Technology & Network [email protected]
Harris CorporationGovt. Communications Systems DivisionP.O. Box 37Melbourne, Florida 32902-0037http://www.harris.com/
Contact Information