Thesis presented in partial fulfilment of the requirements for the degree of Diploma-
Engineer of Mechanical Engineering at the University of Dortmund/Germany in cooperation with the Department of Industrial Engineering of the University of Stellenbosch/South Africa.

Design Reviews and their Impacts on the Enterprise Life Cycle

By Marc Noyen
2004

Abstract

The design and development of general Product Life Cycles (PLC) and Enterprise Life Cycles (ELC) has received significant attention over the past years. The EDENTM Software Environment developed from Indutech (Pty) Ltd provides roadmaps for both life cycles. These roadmaps allow the involved development team to follow a predefined step-by-step structure for their respective project.
As a PLC always belongs to a superior ELC, both life cycles cannot be considered independently. Changes and decisions of one of the life cycles usually have an impact on the other. And although the PLC and ELC are well explored, there does not exist a model which reveals those important interfaces between both life cycles.
This thesis aims on the detection of impacts of the PLC on the ELC. As the Design Review (DR) is a crucial key control element in the development process, the detection of the links is done by means of such DR. After giving general information about DR and providing definitions and descriptions of DR in the PLC and ELC, an impact-matrix is developed which shows the detected interference of the ELC by decisions of DR conducted in the PLC.

Table of contents

Design Reviews and their Impacts on the Enterprise Life Cycle

Declaration ...  iii

Acknowledgements  ... iv

Abstract ... v

Table of contents  ... vi

List of Abbreviations  ... x

List of Figures ... xii

List of Tables  ... xiii

CHAPTER 1: Introduction of the Thesis ... 1
1.1 Introduction  ... 1
1.2 Objectives ... 2
1.3 Structure  ... 2

CHAPTER 2: Design Review – A Key Design Control Element  ... 4
2.1 Introduction  ... 4
2.2 What is Design Review?  ... 4
2.2.1 DO and CO and the need for DR ... 4
2.2.2 Definitions of Design Review  ... 6
2.2.3 Purpose of Design Reviews ... 7
2.2.4 Design Review Teams ... 8
2.2.5 Conducting DR ... 11
2.2.6 Number of DR ... 11
2.2.7 Checklists as a tool in DR  ... 11
2.3 The Product- and the Enterprise Life Cycle ... 12
2.3.1 Introduction  ... 12
2.3.2 Product Life Cycle ... 13
2.3.3 Enterprise Life Cycle ... 20
2.3.4 Involvement of PLC and ELC ... 25

CHAPTER 3: Design Reviews in PLC and ELC  ... 27
3.1 Introduction  ... 27
3.2 Design Reviews in PLC  ... 27
3.2.1 Project Initialisation Meeting  ... 28
3.2.2 System Requirements Review ... 29
3.2.3 System Design Review ... 29
3.2.4 Preliminary Design Review ... 30
3.2.5 Critical Design Review ... 31
3.2.6 Production Readiness Review  ... 31
3.2.7 Product Strategy Review  ... 32
3.3 Design Reviews in ELC  ... 33
3.3.1 Project Initialisation Meeting  ... 34
3.3.2 System Requirements Review ... 34
3.3.3 System Design Review ... 35
3.3.4 Preliminary Design Review ... 36
3.3.5 Critical Design Reviewv 37
3.3.6 Commission Review ... 38
3.3.7 Operational Review ... 38
3.3.8 Disposal Review ... 39

CHAPTER 4: Impacts of Design Review ... 40
4.1 Introduction  ... 40
4.2 Intra Phase Impact ... 42
4.3 Intra Product Life Cycle Impact or Inter Phase Impact  ... 43
4.4 Inter Product Life Cycle Impact ... 43
4.5 Intra Enterprise Life Cycle Impact ... 44

CHAPTER 5: Impacts of product-related DR on the entire Enterprise ... 45
5.1 Introduction  ... 45
5.2 Effects of PIM of PLC on the ELC  ... 46
5.2.1 Concept Phase  ... 46
5.2.2 Definition Phase  ... 47
5.2.3 Design Phase  ... 48
5.2.4 Construction Phase  ... 48
5.2.5 Operation Phase ... 48
5.2.6 Disposal Phase ... 49
5.3 Effects of SRR of PLC on the ELC ... 49
5.3.1 Concept Phase  ... 50
5.3.2 Definition Phase  ... 50
5.3.3 Design Phase  ... 51
5.3.4 Construction Phase  ... 52
5.3.5 Operation Phase ... 52
5.3.6 Disposal Phase ... 52
5.4 Effects of SDR of PLC on the ELC  ... 53
5.4.1 Concept Phase  ... 53
5.4.2 Definition Phase  ... 53
5.4.3 Design Phase  ... 54
5.4.4 Construction Phase  ... 54
5.4.5 Operation Phase ... 55
5.4.6 Disposal Phase ... 55
5.5 Effects of PDR of PLC on the ELC  ... 55
5.5.1 Concept Phase  ... 56
5.5.2 Definition Phase  ... 56
5.5.3 Design Phase  ... 57
5.5.4 Construction Phase  ... 58
5.5.5 Operation Phase ... 58
5.5.6 Disposal Phase ... 59
5.6 Effects of CDR of PLC on the ELC ... 60
5.6.1 Concept Phase  ... 60
5.6.2 Definition Phase  ... 61
5.6.3 Design Phase  ... 61
5.6.4 Construction Phase  ... 61
5.6.5 Operation Phase ... 62
5.6.6 Disposal Phase ... 62
5.7 Effects of PRR of PLC on the ELC ... 62
5.7.1 Concept Phase  ... 62
5.7.2 Definition Phase  ... 63
5.7.3 Design Phase  ... 64
5.7.4 Construction Phase  ... 65
5.7.5 Operation Phase ... 66
5.7.6 Disposal Phase ... 66
5.8 Effects of PSR of PLC on the ELC  ... 67
5.8.1 Concept Phase  ... 67
5.8.2 Definition Phase  ... 67
5.8.3 Design Phase  ... 68
5.8.4 Construction Phase  ... 69
5.8.5 Operation Phase ... 69
5.8.6 Disposal Phase ... 70

CHAPTER 6: Summary of the Thesis ... 72
6.1 Conclusions  ... 72
6.2 Limitations  ... 72
6.3 Perspectives and Recommendations for Future Research ... 73

CHAPTER 7: References  ... 74

CHAPTER 8: Appendices  ... 77
Appendix A: Business Principles Definitions  ... 77
Appendix B: PLC-ELC-Matrix  ... 78

List of Figures

Figure 1-1 Customer-Product-Enterprise Relations  ... 2
Figure 1-2 Structure of the Thesis ... 3
Figure 2-1 Distinction between Design- and Control Objectives  ... 5
Figure 2-2 The Design Process  ... 6
Figure 2-3 Example of a Checklist in EDENTM /EDEN03c/  ... 12
Figure 2-4 The Product Life Cycle ... 13
Figure 2-5 The Enterprise Life Cycle ... 20
Figure 2-6 The PLC builds a Part of the ELC /FISC03/  ... 26
Figure 3-1 Design Reviews in the Product Life Cycle ... 27
Figure 3-2 Design Reviews in the Enterprise Life Cycle ... 34
Figure 4-1 Areas of Influence of DR conducted in the PLC of Product A  ... 40
Figure 4-2 Different Impacts of DR conducted in a PLC within the Enterprise ... 41
Figure 5-1 Structure of the PLC-ELC-Matrix ... 46

List of Tables

Table 2-1 Design Review Team Member /KAPU92/ ... 10

CHAPTER 1: Introduction of the Thesis

1.1 Introduction

It is generally acknowledged that companies today face a dynamic environment, changing at an increasingly rapid pace /VOLB96/ /AVEN94/. To maintain competitiveness, the engineering team involved in the product development process is forced to develop cheaper, better, innovative, and more importantly, faster. The requirements of shortening the time-to-market and quickly adapting to rapidly changing customer and market needs have a huge impact on the Product Life Cycle /MORI99/.
On the other hand also the whole enterprise keeps changing. Nothing is permanent in the business, manufacturing practice, organisational structure or in the information technology infrastructure of an enterprise, not even for months. The design of an enterprise may take a long time and involve many people. As a matter of fact enterprises change more often than the design of any product, and often decisions within the product development are the cause of these changes /BERN94/.
In Figure 1-1 the relations between customer, product and enterprise are illustrated. The customer or the market determines requirements for the product. And the developed product-solution according to the customer requirements again determines the requirements for manufacturing the product within the enterprise. For instance the application of innovative materials for the product-solution implies the correct handling of those materials. This involves acquisition of new technologies and equipment and training of personnel on the new equipment.
The considerations show the strong interactions between the product and its appropriate enterprise. Although the Product- and the Enterprise Life Cycles are well known, defined and explained, and innovative roadmaps of both life cycles for guiding the design team step-by-step through the design process are provided, the interactions between the life cycles are still quite unexplored.

Figure 1-1 is in the Downloadfile

FIGURE 1-1 CUSTOMER-PRODUCT-ENTERPRISE RELATIONS

1.2 Objectives

The Design Review (DR) represents an important key control element of a life cycle. The decisions made during this review have an impact on several areas of the entire enterprise environment.
The first objective of this thesis is to provide a generic definition and description of DR for the Product Life Cycle (PLC) and the Enterprise Life Cycle (ELC), which can be used for product development and enterprise establishment.
In the next step those information is used to determine interactions and impacts between both life cycles by means of DR conducted in the PLC. The results can be used to be aware of effects decisions in the PLC have on the enterprise and to predict in early development stages of the product its impacts on the ELC (e.g. allow to make statements in the Concept Phase of a product about its resulting influences on the Design- or Construction Phase of the ELC).

1.3 Structure

First the thesis gives general information about DR including definitions, purposes and benefits of those reviews. Furthermore, the structure of the involved review team is Introduction of the Thesis 3 pointed out and information about conducting those reviews and about the function of checklists is provided. Then the PLC and the ELC with their respective phases are introduced prior suitable definitions of all DR in both life cycles are presented. Afterwards the different areas of impact of the DR are explained. With this information the interfaces between the PLC and ELC can be detected by means of DR conducted in the PLC. These considerations build the main part of the thesis.
The overall structure of the thesis is illustrated in Figure 1-2. In the figure three different layers allow the assignment of the several points to an area of general considerations and information, to the PLC or to the ELC.

Figure 1-2 is in the Downloadfile

FIGURE 1-2 STRUCTURE OF THE THESIS

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