Introducing SE @ GKN · 3 Stakeholder‐Workshop –Potentials and Benefit 2 Definition SE Process...

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Introducing SE @ GKN ProSTEP iViP Symposium 2017 Michael Engelmann, Dr. Sven Kleiner | May 18 th , 2017

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Transcript of Introducing SE @ GKN · 3 Stakeholder‐Workshop –Potentials and Benefit 2 Definition SE Process...

  • Introducing SE @ GKNProSTEP iViP Symposium 2017Michael Engelmann, Dr. Sven Kleiner | May 18th, 2017

  • 2

    Our Strategy

    Creating long-term shareholder value

    Three strong divisions

    Lead in chosen markets

    Leverage global footprint

    Technology driving margin

    Operational excellence

    Increasing cash flow, EPS and dividends

    BUSINESS PERFORMANCE

    Growth target: Above market

    Group target:8-10%

    Target: 20%

    Sustain above market growth

    Cash Flow

    Growth

    ROICMargin

    Five strategic objectives

  • 3

    GKN Driveline - Overview

    Brazil

    India

    U.K.FranceSpainItalySloveniaTurkey

    Malaysia

    Thailand

    ColombiaSingapore

    Taiwan

    JapanUnited States

    China

    South Korea

    Australia

    Mexico

    Manufacturing plant

    Joint Venture

    Corporate office / Engineering centre

    SwedenPolandGermany

    Russia

  • 4

    A complete driveline solution

    Leadership in all major product lines

    eTransmission

    eAxle coaxdisconnect

    eTwinster

    eAxle -system

    eAxle -fully integrated

  • 5

    Recognized Performance

  • 6

    Drivers and justification

    Why Systems Engineering?

  • 7

    Does this PDP look familiar sometimes?

    Quick bill of material driven decisions suggest efficiency (re-use, little arguing,) and management controlGroup consensus generated in large phone conferences

    Timing constraints enlarges blind sidesReduced prototype stages and test duration required to meet lead times

    Defect detection often late on system level when all comes together and Engineering spends explode

    Requirements engineering

    Racing developmentin domains andfunctional silos

    Mission statement

    Software fixes it..

  • 8

    Imminent need for a Cultural Change

    We have an imminent need for a cultural change despite and because of

    Over 250 years of mechanical product historyA strong production excellence / best practise backgroundAn extensive generic off-the-shelf product line-upStage gate driven, waterfall type progamme management processesA mature and leading driveshaft (CVJ) core business

    Now being faced with

    Rapidly growing All Wheel Drive and eDrive segments in a challenging marketMergers & acquisition impactIncreasing product complexity (mechatronic system of systems)Strongly increasing team sizes and diversitiesShorter product cyclesIncreasing legal requirements, product responsibility and integration depthGlobal mega platforms

    Req

    uire

    sus

    to

    Manage very steep learningcurvesHandle much more complexinterfacesAlign greater teams and roles diversityTake quick and informeddecisions

    Prepare our culture for thechallenges to come

  • [email protected] structured approach & Roadmap

  • 10

    V-Model according to VDI 2206 and Systems Engineering

    System DevelopmentSystem

    IntegrationSystemAnalysis

    ComponentTesting

    Validation

    Verification

    Integration

    RequirementsEngineering

    FunctionalDesign

    LogicalDesign

    PhysicalDesign

    SoftwareModels

    Iterations

    MBE

    MBE

    MBE

    Systems engineering interdisciplinary approach realization of successful

    systems based on RFLP.(INCOSE SE Handbook)

    The challengeis to integrateRequirements,Functional,Logical andPhysical Architecture.

    Joe Sutter, Boeing 747 Chief Eng.

  • 11

    Model-Based Systems Engineering (MBSE)

    ModelBasedSystemsEngineering

    Organization Process

    Requirement modelFunctional modelFunctional model

    Architecture modelArchitecture modelParameter modelParameter model

    Systems Engineering ModelSystemEngineer

    Req

    uire

    men

    ts,

    Arch

    itect

    ure,

    Pa

    ram

    eter

    s

    (Multi-)Physical ModelsMCADMCAD ECADECAD SoftwareSoftware BehaviorBehavior CAE CAE

    ComponentEngineers

    Attri

    bute

    s.Be

    havi

    or

  • 12

    Workshop Concept: (MB)SE Roadmap within 20 days!

    SE/MBSESpecificationandRoadmap8

    DefinitionofSE/MBSEImplementationSteps(Processes,Methods,Tools,Interfaces)7

    Collectionand PrioritizationofSE/MBSEInitiatives6

    AnalysisofITPlatformforSE/MBSEandnecessaryInterfaces5

    AnalysisofUseCasesandTopicsSE REQ Fct SA MBSE 1DS

    4

    StakeholderWorkshop PotentialsandBenefit3

    DefinitionSEProcessCoverage2

    SE/MBSEProject KickOff1

  • 13

    Workshop Concept

    Applied Consulting ApproachEnable Systems Thinking basics in dedicated workshopsEstablish SE core concepts (e.g. R-F-L-P)Reflect current pain points & derive critical success factors for SE adoptionDevelop GKN-specific views on SE topicsIntegrate external impulses on out-of-sight-topicsCreate hands-on experience on SE approach (external & internal examples)Master SE roadmap development on GKNs own with external reviewDevelop deployment strategy

  • 15

    [email protected]

    SEinitiativesSystemsThinking&SECommunication Analysis MS1 Specification MS2 Implementation&Rollout MS3

    SystemsModeling Analysis&Specification Implementation MS2 Deployment/Rollout MS3

    Analysis Specification&Concepts MS2Implementation Rollout MS3

    SystemsIntegration&Validation Analysis Specification MS2 Implementation MS3

    RequirementsEngineering Analysis&Concept MS1 Methods Tools/Integration MS3 Rollout&Improvements MS4

    FMEAinSystemsEngineering Analysis MS1 Methods/Process Tool/Imp MS3 Rollout MS4 ContinuousImprovement

    MS1 Analysis Methods,Guidelines&Process MS2.1MS1 Implementation&Rollout,Correlation1DtoTest MS2.2 MS3

    ProjectMarketing Analysis Network MS1 Comingout MS2 PublicRelations

    Caption: WorkpackagesMilestone,synchronisationwithotherinitiatives

    1DSimulation

    MS1

    MS1

    MS1

    MS2

    MS2

    SystemsDevelopmentofxBlocks

    Q1 Q2 Q3 Q7 Q8 Q9 Q10Q4 Q5 Q6

    From One-Pager to SE Initiatives to SE Roadmap

  • 16

    The 8 GKN Key SE Initiatives

    1. Systems Thinking and SE Communication

    2. Systems Modeling

    3. Systems Development & X Blocks

    4. Systems Integration & Validation

    5. Requirements Engineering

    6. FMEA / Functional Safety in SE

    7. 1D Simulation

    8. Project Marketing

    [email protected]: WBS for SE-Initative "Requirements Engineering" (RQE)

    FTE d 176,00 FTE d 130,00 FTE d 140,00 FTE d 260,00FTE d 71,50 FTE d 37,00 FTE d 245,00 FTE d 140,00Invest 0 Invest - Invest - Invest -

    REQ - PHASE 1: ANALYSE UND KONZEPTION (MS1: 31.12.16) REQ - PHASE 2: Methoden (MS2: 31.03.17) REQ - PHASE 3: Tools (MS3: 30.09.17) REQ - PHASE 4: Rolout (MS3: 31.12.17)

    31,00 20,00 55,00 18,50 35,00 11,00 20,00 7,00 35,00 15,00 130,00 37,00 80,00 160,00 60,00 85,00 260,00 140,00

    AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest () AP FTE (int) FTE (ext) Invest ()Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning Start Base plan Planning

    1.1 4,00 2.1 10,00 9,00 3.1 15,00 5,00 4.1 10,00 3,00 5.1 10,00 8,00 6.1 20,00 7,00 7.1 20,00 100,00 8.1 10,00 20,00 9.1 80,00 50,00

    1.2 10,00 3,00 2.2 10,00 4,00 3.2 15,00 5,00 4.2 5,00 3,00 5.2 20,00 6,00 6.2 45,00 20,00 7.2 10,00 20,00 8.2 20,00 30,00 9.2 80,00 50,00

    1.3 2,00 4,00 2.3 10,00 1,50 3.3 4.3 6.3 45,00 10,00 7.3 20,00 20,00 8.3 10,00 35,00 9.3 80,00 40,00 50.000,00

    1.4 4,00 4,00 2.4 10,00 1,50 3.4 7.4 10,00 20,00

    1.5 10,00 4,00 2.5 10,00 1,50 3.5

    5,00 1,00 5,00 1,00 5,00 1,00 5,00 1,00 5,00 1,00 20,00 20,00 20,00 20,00

    AP Projektmanagement AP Projektmanagement AP Projektmanagement

    0% 0% 0%

    AP Projektmanagement AP Projektmanagement AP Projektmanagement

    0% 0%

    AP Projektmanagement AP Projektmanagement AP Projektmanagement

    0% 0%

    0% 0% 0%0% 0% 0%

    AP1.5 Auswertung Templates AP2.5 Dokumentation use cases

    0% 0% 0%

    AP7.4 Rollendefinitionen, Rechtemanagement

    0% 0%0% 0% 0%

    AP1.4 Analyse Templates AP2.4 Dokumentation Prozesse

    0% 0% 0%

    AP7.3 Templates AP 8.3 Partnerintegration (z.B. Supplier Portal)AP9.3 Anwender bezogener Support und

    Training

    0% 0% 0%

    AP6.3 Modularisierung Lastenheft / Pflichtenheft

    0% 0% 0%

    AP1.3 Interviewleitfahden AP2.3 Dokumentation der IT-Umgebung

    0% 0% 0%

    AP7.2 Traceability AP8.2 Anbindung von Testmanagement (PTE)AP9.2 Kontinuierliche Verbesserung / condition

    monitoring

    0% 0% 0%

    AP4.2 Erstellung Entscheidungsvorlage Management AP5.2 Planung Pilotprojekte AP6.2 Vorlagenerarbeitung

    0% 0% 0%

    AP1.2 Analyse der Dokumentation AP2.2 Durchfhrung der Reviewworkshops AP3.2 Dokumentation Soll Prozess

    0% 0% 0%

    AP7.1 Prozesse RQE AP8.1 Anbindung von angrenzeden Prozessen und Systemen AP9.1 Rollout und Verwendung

    0% 0% 0%

    AP4.1 Erstellung Projektplan Einfhrungsprojekt

    AP5.1 Detaillierung Handlungsempfehlung und Quick-Wins AP6.1 RQE Methoden (Erstellung, Prfung)

    0% 0% 0%

    AP1.1 Vorgehensmodell AP2.1 Durchfhrung der neun Themenworkshops AP3.1 Dokumentation der Analyse

    0% 0% 0%

    Progr. % Progr. % Progr. % Progr. % Progr. % Progr. % Progr. % Progr. % Progr. %

    AP7 Implementation toolkette AP8 Anbindung AP9 Rollout

    0% 0% 0% 0% 0% 0% 0%

    AP1 Initialisierung und Konzepterstellung fr Analyse AP2 Durchfhrung der RQE-Analyse AP3 Auswertung der Analyse

    AP4 Ausarbeitung und Abstimmung Konzeption Einfhrungsprojekt AP5 Quick-Wins in Pilotprojekten

    AP6 Methoden, Standards, Modularisierung

    0% 0%

    Systems Engineering at GKN is a holistic approach to ensure the requirement focused technology process.

  • 17

    Initiatives andExamples

  • 18

    SE Initiatives Focus - Prioritization

    SE Initiative Overall ranking

    Requirements Engineering 1

    Systems Thinking and Systems Modeling 2

    Systems Development & X Blocks 3

    Systems Integration & Validation 4

    FMEA in SE 5

    1D Simulation 6

    Project Marketing Parallel activitiy

  • 19

    1. Requirements Engineering @ GKN Yesterday and Today

    E/E and Software (A-SPICE conform) Mechanics with database driven Excel formats

  • 20

    1. Requirements Engineering @ GKN Today and Tomorrow

    Inherent process differences like Ownership No. of programmes being handled Required reaction speed Complexity of requirements analysis and tracing Lifecycle states / product maturity Resource availability

    favor a 2 step approach :

    RQE 1.0 Frontend

    RQE 2.0 Full Application

    ReqIFInterface

    1.0 Winning the business: High level risk assessment andinitial product selection with documented compliancematrix

    2.0 Delivering the business: Detailed requirementsengineering with full traceability, workflow modeling andlinks into PDM and verification / validation

  • 21

    2. Systems Modeling: RFLP approach (Example eTwinster Project)

    Systematic system analysis according to RFLP

    approach Model based requirements engineering with

    Stakeholder analysis

    Use case analysis

    System context analysis

    System states development

    Systematic decomposition of the eTwinster using

    SysML with context- and user-dependent views

    Functional structure

    Logical architecture

    Identification of additional requirements and

    alignment need

    VehicleSystem-of-Systems

    eTwinster

    Inputperiphery

    Outputperiphery

    Humans

    Environment

    EM1

    EF2

    EF1

    AM1

    AF2

    AF1

    EU1AU1

    VehicleSubsystemn

    VehicleSubsystemm

    VehicleSubsystem1

    Vehi

    cle

    Subsystem2

    EF2SS

    EF1SS

    Vehi

    cle

    Subsystem3

    AF2SS

    AF1SS

  • 22

    2. Systems Modeling: RFLP approach (Example eTwinster Project)

    Systematic system analysis according to RFLP

    approach Model based requirements engineering with

    Stakeholder analysis

    Use case analysis

    System context analysis

    System states development

    Systematic decomposition of the eTwinster using

    SysML with context- and user-dependent views

    Functional structure

    Logical architecture

    Identification of additional requirements and

    alignment need

  • 23

    3. Systems Thinking (Example eTwinster Project)

    Use of systems thinking tracks for holistic

    analysis of GKN systems e.g. dynamic thinking, life-cycle thinking, risk

    and safety thinking

    Tracksaccordingto:Gerrit MaartenBonnema,JanF.Broenink:ThinkingTracksforMultidisciplinarySystemDesign

  • 24

    Deployment Strategy

  • 25

    SE Deployment Strategies

    Basic deployment approaches

    Top-down

    Limited buy-in, must-

    do

    Bottom-up

    Nojustification, should-not-

    do

    Wrench

    Middlemanagement

    cannotescape

    Viral

    Creates pull, but likely to become

    badly alignedislands

    Wedge

    No support in execution level

    or resourcejustification

    The GKN Approach

  • 26

    Exemplary Deployment Activities

    Global roadshows, workshops

    Cross-divisional synergy meetings(GKN Aerospace)

    Standardized process landscapes(DES, CAPM)

    Standardized roles

    SE specific programme reviews

    SE data pool in iShare

    Newsticker, Intranet presence

    Roadmap and strategic 5 year plan

    SE office

    CI Plan integration of SE

    Train the trainers (moderator training)

    MBSE pilot workshops create pull in projectteams

    Simple, easy - entry tool landscape

    SE network

  • 27

    Supporting Activities

  • 28

    Supporting Activities

    Requirements Engineer Catches the problem

    System Engineer Defines the solution

    Programme Engineer Brings the team to succeed

    SE

  • 29

    Supporting Activity: Training Concept

    Acade-mia

    Rea

    chPublic Mate-

    rial

    External Training Roles Specific

    ExternalTraining GenericContent

    GKN Academy

    Viral Spread

    Key Note Speakers

    SE Progr. Reviews

    iShareData Pool

    Bubble size denotes effort Effectivity

  • 30

    Benefits and Outlook

  • 31

    Practical quick wins

    Systems Thinking Sharing the vision, aligning domain languages and

    philosophy Creating common values and views

    Requirements engineering Creating common starting grounds Clarifying and aligning targets

    MBSE Fostering communication Aligning views and bridging barriers Triggering questions and conflict resolution Enforcing alignment and agreement Supporting global re-use

    1D Simulation Improve behavioural understanding up to vehicle level

    SE Marketing Increasing Management Support Opening mindsets Questioning existing organizational models

  • 32

    MBSE Outlook: System Integration / Validation

    Systematic development of testing strategy for eTwinster system based on system model

  • 33

    MBSE Outlook: 1-D-Simulation Integration

    Realization of an interface between SysML-model

    and simulation model, e.g. based on FMI/FMU

    Simulation model in AMESim and SimulinkSysML Model of eTwinster

  • 34

    Outlook: Integrated or Linked Product Safety Approach

    Vehicle Component(Form Sheet)Properties

    (Material/Geometry)

    Functions 1 Function 2b Function 3b Function 4 Characteristic 5

    Failure 1 Failure 2 Failure 3 Failure 4 Failure 5

    Effect Failure CauseEffect Failure Cause

    S-FMEAD-FMEA

    Function 2afrom requirements

    System requirements

    OEM system requirements

    PTC IntegritySafety requirements

    Safety /FuSi

    severity ASIL

    occurrence /detection

    DVP&RPTE Tasks

    severity

    Lesson learned / GKN STD

    GKN Know HowGeneric / STD requirements

    HRS/SRS

    Function 3afrom HRS/SRS

    System(Form sheet)

    import/export and cross check

    Sub-System

    System tests

    Component test /Sub-system tests

    feedback

    RPNoccurrence /

    detectionRPN

    feedback

    Characteristic 3

  • 35

    The leader in contemporary and hybrid electric drivetrain technology