System Engineering Management

Systems Engineering Management, Fifth Edition is a practical guide to the tools and methodologies used in the field. Using a "total systems management" approach, this book covers everything from initial establishment to system retirement, including design and development, testing, production, operations, maintenance, and support. This new edition has been fully updated to reflect the latest tools and best practices, and includes rich discussion on computer-based modeling and hardware and software systems integration. New case studies illustrate real-world application on both large- and small-scale systems in a variety of industries, and the companion website provides access to bonus case studies and helpful review checklists. The provided instructor's manual eases classroom integration, and updated end-of-chapter questions help reinforce the material. The challenges faced by system engineers are candidly addressed, with full guidance toward the tools they use daily to reduce costs and increase efficiency.

System Engineering Management integrates industrial engineering, project management, and leadership skills into a unique emerging field. This book unifies these different skill sets into a single step-by-step approach that produces a well-rounded systems engineering management framework.

• Learn the total systems lifecycle with real-world applications
• Explore cutting edge design methods and technology
• Integrate software and hardware systems for total SEM
• Learn the critical IT principles that lead to robust systems

Successful systems engineering managers must be capable of leading teams to produce systems that are robust, high-quality, supportable, cost effective, and responsive. Skilled, knowledgeable professionals are in demand across engineering fields, but also in industries as diverse as healthcare and communications. Systems Engineering Management, Fifth Edition provides practical, invaluable guidance for a nuanced field.

BENJAMIN S. BLANCHARD is Professor Emeritus, Department of Industrial and Systems Engineering, Virginia Polytechnic Institute & State University. He serves as consultant in such fields as systems engineering, reliability, maintainability, and lifecycle costing.

JOHN E. BLYLER is the founding advisor and affiliate professor of the Systems Engineering Graduate Program at Portland State University. He has considerable experience in hardware-software systems engineering and management, both in industry and government.

Preface xi

1 Introduction to System Engineering 1

1.1 Definition of a System / 2

1.1.1 The Characteristics of a System / 2

1.1.2 Categories of Systems / 5

1.1.3 System of Systems (SOS) / 8

1.2 The Current Environment: Some Challenges / 9

1.3 The Need for System Engineering / 15

1.3.1 The System Life Cycle / 16

1.3.2 Definition of System Engineering / 18

1.3.3 Requirements for System Engineering / 25

1.3.4 System Architecture / 26

1.3.5 System Science / 26

1.3.6 System Analysis / 27

1.3.7 Some Additional System Models / 28

1.3.8 System Engineering in the Life Cycle (Some Applications) / 32

1.4 Related Terms and Definitions / 34

1.4.1 Concurrent/Simultaneous Engineering / 35

1.4.2 Some Major Supporting Design Disciplines / 36

1.4.3 Logistics and Supply-Chain Management (SCM) / 38

1.4.4 Integrated System Maintenance and Support / 40

1.4.5 Data and Information Management / 43

1.4.6 Configuration Management (CM) / 44

1.4.7 Total Quality Management (TQM) / 45

1.4.8 Total System Value and Life-Cycle Cost (LCC) / 45

1.4.9 Some Additional Terms And Definitions / 46

1.5 System Engineering Management / 47

1.6 Summary / 51

Questions and Problems / 51

2 The System Engineering Process 53

2.1 Definition of the Problem (Current Deficiency) / 55

2.2 System Requirements (Needs Analysis) / 56

2.3 System Feasibility Analysis / 57

2.4 System Operational Requirements / 59

2.5 The Logistics and Maintenance Support Concept / 62

2.6 Identification and Prioritization of Technical Performance Measures (TPMs) / 69

2.7 Functional Analysis / 74

2.7.1 Functional Flow Block Diagrams (FFBDs) / 77

2.7.2 Operational Functions / 80

2.7.3 Maintenance and Support Functions / 80

2.7.4 Application of Functional Analysis / 81

2.7.5 Interfaces with Other Systems in a SOS Configuration / 88

2.8 Requirements Allocation / 90

2.8.1 Functional Packaging and Partitioning / 90

2.8.2 Allocation of System-Level Requirements to the Subsystem Level and Below / 92

2.8.3 Traceability of Requirements (Top-Down/Bottom-Up) / 95

2.8.4 Allocation of Requirements in a SOS Configuration / 95

2.9 System Synthesis, Analysis, and Design Optimization / 97

2.10 Design Integration / 105

2.11 System Test and Evaluation / 108

2.11.1 Categories of Test and Evaluation / 110

2.11.2 Integrated Test Planning / 112

2.11.3 Preparation for Test and Evaluation / 113

2.11.4 Test Performance, Data Collection, Analysis, and Validation / 115

2.11.5 System Modifications / 115

2.12 Production and/or Construction / 117

2.13 System Operational Use and Sustaining Support / 118

2.14 System Retirement and Material Recycling/Disposal / 120

2.15 Summary / 121

Questions and Problems / 122

3 System Design Requirements 125

3.1 Development of Design Requirements and Design-To Criteria / 128

3.2 Development of Specifications / 129

3.3 The Integration of System Design Activities / 135

3.4 Selected Design Engineering Disciplines / 139

3.4.1 Software Engineering / 139

3.4.2 Reliability Engineering / 144

3.4.3 Maintainability Engineering / 159

3.4.4 Human-Factors Engineering / 174

3.4.5 Safety Engineering / 185

3.4.6 Security Engineering / 187

3.4.7 Manufacturing and Production Engineering / 189

3.4.8 Logistics and Supportability Engineering / 191

3.4.9 Disposability Engineering / 199

3.4.10 Quality Engineering / 200

3.4.11 Environmental Engineering / 204

3.4.12 Value/Cost Engineering (Life-Cycle Costing) / 207

3.5 SOS Integration and Interoperability Requirements / 215

3.6 Summary / 216

Questions and Problems / 219

4 Engineering Design Methods and Tools 223

4.1 Conventional Design Practices / 225

4.2 Analytical Methods / 228

4.3 Information Technology, the Internet, and Emerging Technologies / 229

4.4 Current Design Technologies and Tools / 231

4.4.1 The Use of Simulation in System Engineering / 235

4.4.2 The Use of Rapid Prototyping / 235

4.4.3 The Use of Mock-Ups / 236

4.5 Computer-Aided Design (CAD) / 237

4.6 Computer-Aided Manufacturing (CAM) / 245

4.7 Computer-Aided Support (CAS) / 246

4.8 Summary / 248

Questions and Problems / 249

5 Design Review and Evaluation 251

5.1 Design Review and Evaluation Requirements / 252

5.2 Informal Day-to-Day Review and Evaluation / 256

5.3 Formal Design Reviews / 262

5.3.1 Conceptual Design Review / 264

5.3.2 System Design Reviews / 265

5.3.3 Equipment/Software Design Reviews / 266

5.3.4 Critical Design Review / 267

5.4 The Design Change and System Modification Process / 269

5.5 Supplier Review and Evaluation / 272

5.6 Summary / 274

Questions and Problems / 274

6 System Engineering Program Planning 275

6.1 System Engineering Program Requirements / 278

6.1.1 The Need for Early System Planning / 278

6.1.2 Determination of Program Requirements / 280

6.2 System Engineering Management Plan (SEMP) / 282

6.2.1 Statement of Work / 285

6.2.2 Definition of System Engineering Functions and Tasks / 286

6.2.3 System Engineering Organization / 293

6.2.4 Development of a Work Breakdown Structure (WBS) / 296

6.2.5 Specification/Documentation Tree / 303

6.2.6 Technical Performance Measures (TPM) / 309

6.2.7 Development of Program Schedules / 310

6.2.8 Preparation of Cost Projections / 324

6.2.9 Program Technical Reviews and Audits / 328

6.2.10 Program Reporting Requirements / 329

6.3 Determination of Outsourcing Requirements / 332

6.3.1 Identification of Potential Suppliers / 334

6.3.2 Development of a Request for Proposal (RFP) / 336

6.3.3 Review and Evaluation of Supplier Proposals / 337

6.3.4 Selection of Suppliers and Contract Negotiation / 344

6.3.5 Supplier Monitoring and Control / 351

6.4 Integration of Design Specialty Plans / 353

6.5 Interfaces with Other Program Activities / 355

6.5.1 Interface Management / 359

6.6 Management Methods/Tools / 360

6.7 Risk Management Plan / 361

6.8 Global Applications/Relationships / 366

6.9 Summary / 367

Questions and Problems / 369

7 Organization for System Engineering 372

7.1 Developing the Organizational Structure / 373

7.2 Customer, Producer, and Supplier Relationships / 374

7.3 Customer Organization and Functions / 376

7.4 Producer Organization and Functions (the Contractor) / 378

7.4.1 Functional Organization Structure / 379

7.4.2 Product-Line/Project Organization Structure / 383

7.4.3 Matrix Organizational Structure / 384

7.4.4 Integrated Product and Process Development (IPPD) / 387

7.4.5 Integrated Product/Process Teams (IPTs) / 389

7.4.6 System Engineering Organization / 390

7.5 Tailoring the Process / 396

7.5.1 Tailoring the Process / 400

7.5.2 Middle-Out Approach / 401

7.5.3 Managing from the Middle / 404

7.6 Supplier Organization and Functions / 406

7.6.1 Mapping Organization and Systems Structures / 409

7.7 Human Resource Requirements / 411

7.7.1 Creating the Proper Organizational Environment / 411

7.7.2 Leadership Characteristics / 414

7.7.3 The Needs of the Individual / 415

7.7.4 Staffing the Organization / 419

7.7.5 Personnel Development and Training / 421

7.8 Summary / 423

Questions and Problems / 424

8 System Engineering Program Evaluation 426

8.1 Evaluation Requirements / 428

8.2 Benchmarking / 428

8.3 Evaluation of the System Engineering Organization / 431

8.4 Program Reporting, Feedback, and Control / 437

8.5 Summary / 438

Questions and Problems / 439

Appendix A Functional Analysis (Case-Study Examples) 440

Appendix B Cost Process and Models 447

Appendix C Selected Case Studies (Nine Examples) 481

Appendix D Design Review Checklist 529

Appendix E Supplier Evaluation Checklist 530

Appendix F Selected Bibliography 531

Index 539

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.