systems engineering challenges for management era in manufacturing big data and iot ... october 25,...

June 5th-7th | Cleveland, OHThe Conference on Advancing Analysis & Simulation in Engineering | CAASE18nafems.org/caase18

Systems Engineering - Challenges for Management

MBSE 105

Frank Popielas, Managing Partner & Co-FounderEd Ladzinski, CEO & Co-Founder

SMS_ThinkTank™ LLC

www.smsthinktank.com

1

http://www.smsthinktank.com/

© SMS_ThinkTank™ 6/6/2018 2

Content

➢Market challenges and engineering trends

➢The role of Systems Engineering➢Technology

➢Business

➢The Role of Management – Is Management up to the Challenge?➢Governance

➢Leadership

➢Mentorship

➢???


Engineering Vision

Unification by Design. Systems thinking by

Choice.


Business Challenges➢ Global economy

➢ All are interconnected➢ All are somewhat dependent on each other➢ Huge variety of cultures ➢ Established vs. new upcoming businesses (legacy)

➢ Faster than ever changing / evolving technology➢ Increases pressure on keeping up with competitiveness➢ High-end technology is available almost to all size of businesses now

➢The age of data and information ➢Availability and use of data➢Capturing Tribal Knowledge

➢Digitalization, visualization, and collaboration➢Virtual Reality➢Closed-loop connections between physical and virtual worlds➢Collaboration at all stages of the lifecycle

➢The complexity issue➢ Electronics and embedded software systems➢ Integration into ecosystem

More complex technologies are challenging the ability for middle and upper management to understand the emerging needs of the business


Engineering TrendsSome basic trends

➢Increased complexity➢Products

➢Ecosystem

➢Demand for more flexibility and choices

➢Improved product quality and robustness guarantee

➢Digitalization➢Need for upfront virtual prediction capabilities

➢Real-time and virtual access to information

➢Sustainable innovation ➢Collaboration / partnerships

➢Drastically reduced time-to-market

➢Reduction in overhead costs

➢ Electronics➢ Assemblies➢ Connectivity➢ Materials➢ Sustainability

➢ Company (R&D, manufacturing, IT, …)➢ Environmental concerns➢ Society➢ …

➢ Individual needs➢ Customization➢ Regional➢ Cultural➢ ….

➢ New mfg. processes & materials—lighter, stronger

➢ Increased regulatory requirements across all industries

➢ Optimization➢ In-service support➢ …

➢ Environment➢ Resources➢ Business➢ Society


Engineering TrendsSome basic trends

➢Increased complexity➢Products

➢Ecosystem

➢Demand for more flexibility and choices

➢Improved product quality and robustness guarantee

➢Digitalization➢Need for upfront virtual prediction capabilities

➢Real-time and virtual access to information

➢Sustainable innovation ➢Collaboration / partnerships

➢Drastically reduced time-to-market

➢Reduction in overhead costs

• Companies are operating in an ever leaner environment

• Ever growing demand for accountability


Engineering TrendsAchieving Sustainable Innovation

➢System modeling and simulation➢IIoT and Industry 4.0

➢New era in manufacturing

➢Big Data and IoT➢The way we collect and distribute data is changing rapidly➢New infrastructure needed

➢Iterative and collaborative approaches➢Closed-loop➢Across domains and organizations

➢Cognitive engineering➢Predictive analytics➢Deep learning➢Digital twin

SMS is the use of interdisciplinary functional, architectural, and behavioral models (with physical, mathematical, and logical representations) in performing MBSE (Model-Based Systems Engineering) to specify, conceptualize, design, analyze, verify and validate an organized set of components, subsystems, systems, and processes….. plus

Innovating at the Speed of Thought


“Digitalization” Accelerates Change & Innovation

2016 World Economic Forum


The Complexity Issue

Source: DARPA AVM pres.

➢ System complexity increases

➢ Required time to market decreases (most industries)

➢Without disruptive changes, an impossible equation to solve

➢ The main culprit: (embedded) software complexity

How about autonomous cars?


Engineering Future: Automotive

* source: E-cast – “OSM-RTI_The_Low-Risk_Path_to_Building_Autonomous_Car_Architectures”; October 25, 2016

➢ 6-10 consolidated controllers➢ Consolidated software system➢ Coordinated operations➢ Reduced weight, cost & complexity➢ Future-proof with built-in upgradability


The Complexity Issue

Source: DARPA AVM pres.

➢ Are we integrating the various systems properly?

➢ Aren’t we just releasing product too fast?

➢ Do we have the proper development processes in place?

➢ Do we do a proper systems engineering?

➢Model Based Systems Engineering?

How about autonomous cars?


Volvo

Evolution of Systems: “Systems of Systems” are next in line for Providing Greater Engineering Challenges

Reactive Adaptive Proactive

ProcessProduct

Vehicle

Communications

Network

Nature

Space

Environment

Society

Cognitive

Society, nature and products are universally

interlinked and interconnected with each other utilizing

real-time communication to predict behavior


➢Better Predictability

➢ Improved Validation

➢……..

The Case for Systems Modeling and Simulation

Traditional

Modern

Laggards

Reactive Adaptive Proactive Cognitive

SMS

RequirementsDefine

FunctionalDecompose

LogicalLayout

PhysicalBuilt

VerifyCheck

ValidateTest

Sign-offRelease

Logistic

Manufacturing

Requirements Assessment

Design & Product Development

Layout

Prototype

Simulation &Analysis

Testing

Production Release

Ideation


The engineering “V” and the Life Cycle

The system thinking spans across the entire life cycle, ……

Concept of Operations

System Requirements

High-LevelDesign

DetailedDesign

System Acceptance

Testing

System Testing

SubsystemTesting

ComponentTesting

Physical ModelSoftware / Hardware

Implementation

System Validation

System Verification

Sub-System Verification

Component Verification

Review

DeploymentIn Service

Industry 4.0 / IIoTDigital Twin

IoTDigital Twin


Going Beyond the “V”

Typically, there are several platforms involved to realize all the benefits of having a Digital Twin available. The underlying Product Innovation Platform needs to be able to bring the threads of all those platforms together to ensure that data and information is consistent and not duplicated.

Source: SMS_ThinkTank™, CIMdata


High Level Structure – Organizational Elements

➢Keep its simple

➢Avoid too many layers

➢Make it transparent

➢Communicate

➢Clear messages

Governing Enterprise

SMS Council

Governing Technical Teams

Business Units

EC

All levels need a sponsor

EC – Executive Committee


High Level Structure

➢ Strategy / Concept➢ Strategy

➢ Communication

➢ Marketing

➢ Education

➢ General Processes➢ Stage Gates➢ Engineering Vee

➢ Enabling Area➢ Software➢ Hardware➢ Infrastructure➢ …

➢ Execution Area➢ Structural

➢ Fluid

➢ Mechatronics

➢ Multi-physics

➢ Electrical

➢ Electronics

➢ Pneumatics

➢ Hydraulics

➢ ……

➢ Tools➢ …

SMS is an iterative process throughout the Life Cycle

RequirementsDefine

FunctionalDecompose

LogicalLayout

PhysicalBuilt

VerifyCheck

ValidateTest

Sign-offRelease

Logistic

Manufacturing

Requirements Assessment

Design & Product Development

Layout

Prototype

Simulation &Analysis

Testing

Production Release

Ideation

Organization

Processes

Technologies


*Source: OSM-RTI Webcast “The Inside Story: How the IIC’s Connectivity Framework Guides IIoT Connectivity Selection”; April 2017

retired


The Hype of Systems Engineering* - Where is Management’s Thinking?

/ third

*Utilizing the Gartner Hype Cycle

(2)1. Late Adopters

2. Trying to sort things out

3. Establishing roadmap

4. Leaders


Moving towards Change SuccessThe Change Performance Gap

How important is each of the following to the success of a change initiative, and how well does the organization perform on each of these same factors when implementing the change initiative


Cultural Change: Critical Points of Failure

Based on a Harvard survey:

Percentage indicating which of the following are the biggest barriers to successful change


Data – Processes – Culture - Maturity

Processes are enabling Behavior / Culture defines Behavior

Data is the Foundation

Maturity defines Market Position


Innovation – At the Speed of Thought

Market Position

Enabled Behavior

Innovating at the Speed of Thought

Data Management

Leadership

Operational Management

Leadership

InnovationLeadership

Ability to Lead Change

Predictive Ability

Learning over Time

Reasoned Thinking

Data is the Foundation

Information

Intelligence

Insight

Inspiration

Innovation

SMS


Process➢ How do we start this?

➢ Vision➢ Mission➢ Sponsorship ➢ Lead

➢ How do we go about it?➢ Participation structure

➢ Core team➢ Wider Enterprise ….

➢ Roles & responsibilities

➢ How do we make it happen?➢ Roadmap➢ Accountability➢ Governance structure➢ Communication structure➢ Education

➢ How to maintain it?➢ Governance ➢ …..

Executive Sponsorship

Governance

Execution

Accountability

Mission

Planning

Keep it Simple


Achieving Sustainable Innovation

Opportunity

or Threat Timeframe

Innovation

Maturity

Time

Product

RedesignProduct

Improvement

Function

Innovation

System

Innovation

Innovate or Die!

Each curve has its own stages

Most companies display

nowadays in behavior of

“Incrementality” only.

Innovation leadership

is “Innovating at the

Speed of Thought”.


Achieving Sustainable Innovation

➢Each S-curve typically has its own life cycle as traditionally defined

Innovation Pioneering Growth Maturation Decline Retirement

➢Higher Levels of Innovation Maturity require a new Understanding

Concept Design Build Produce Launch Service

➢With the enablement of IIoT, IoT, DigitalTwin there is additional huge untappedpotential for a product and its related IPwhile in service➢Only mechanical life and user acceptance

decide the remaining life of a product


Application Streams

Keyword: Sustainable Innovation

➢ Establish the proper management infrastructure to enable, guide and mentor, while making and holding people accountable

➢ Going beyond “simulation-driven development”

Governance

Capabilities

ExecutionKeyword: First Time Right

➢ Establish the required processes

Keyword: Technology

➢ Develop, deploy and maintain the required tool set and underlaying foundational infrastructure to enable this


Cultural Change: Gain Acceptance to Advocate

Time

Co

mm

itm

en

t

•Commitment

••

Awareness

Self-concern

Mental Tryout

•

Hands-on

•

Awareness Acceptance Ownership Sustaining

Understanding

Collaboration••

•Advocacy

Based on Source: Dassault Systèmes Business Transformation Consulting

Involvement•


Summary

➢We are in an faster-than-ever changing environment

➢Management needs to understand challenges, trends and benefits of modern engineering

➢Management needs to be a mentor and stay engaged to be able to execute properly

➢Create environment that enables sustainable innovation

➢Keep it simple

June 5th-7th | Cleveland, OHThe Conference on Advancing Analysis & Simulation in Engineering | CAASE18nafems.org/caase18

Thank You!

Frank Popielas: [email protected]

Ed Ladzinski: [email protected]

www.smsthinktank.com

31

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systems engineering challenges for management era in manufacturing big data and iot ... october 25,...

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