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Electronics Engineering Work-flow

08/27/2008 11:35 AM

Hello all,

I work as an Electronics Engineer in an Research and Development Department. It should be mentioned that I do not hold a BSEE degree, only an AS degree. I do however have 15 years of experience so I am not a complete idiot..

My company is going through some pretty big changes and they have asked me to document my "ideal" work-flow from assignment of a project to hand off to Manufacturing.

Now I know what I have always done. Somethings I do are very regimented like the actual design work, I always document everything, keep notes etc.

Were my lack of knowledge and skills come in is in things like Time, Budgets, etc...More the management of the project. And its not really that I don't know how to do these things I am just not sure when the best time during the cycle to do them and if there should be Initial budgets etc and when to finalize them and what other departments do to support an Engineer. (ie purchasing, manufacturing, accounting, marketing etc...)

I have always kind of just did it all myself.

I would like anyone that can to post a simple 1,2,3 of managing a Electronics Engineering Project. from assignment to completion and when do you consider it complete? After you prototype and turn stuff over to manufacturing? or when the first production item ships?

Can you see my dilemma? Am I making sense what I am asking for?

I don't know if there is a standard that EE's get taught in school or if every company just fumbles around tell they figure out what works for them..

Any help would be of great help to me.

Thanks for all you CR4 Peoples help. I don't post much but I sure learn allot. One day maybe I will be smart enough to help too!

Best to all

bill12780

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#1

Re: Electronics Engineering Work-flow

08/27/2008 2:15 PM

Include these steps:

1) get requirements - and get them complete

2) get a schedule together - make it real

3) get a budget that supports your schedule

4) when you have you concept well in hand, hold a preliminary design review - invite purchasing, manufacturing, and the money bags

5) add purchasing and manufacturing to the schedule.

6) when you have a good prototype, hold another design review. Include schedule, procurement, manufacturing and budget in the review, as well as all the engineering fundamentals - design, build, test, qualify, etc.

7) when you get ready to produce the item, hold a manufacturability review, include budget, procurement, manufacturing, test, marketing, etc

8) Don't move from step to step until all of the stakeholers are on board. Don't let go until you're sure that manufacturing has a plan.

I'm sure there are steps I've left out.

BTW - step 1 shouldn't be - Go to CR4 and find out how to do it.

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#2

Re: Electronics Engineering Work-flow

08/27/2008 2:38 PM

When asked for a budget take your best estimate budget and double it.

When asked for a timeframe take your 'smooth sailing' timeframe and triple it.

This approach has proven to be remarkably accurate over the years.

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#5
In reply to #2

Re: Electronics Engineering Work-flow

08/27/2008 6:09 PM

"When asked for a budget take your best estimate budget and double it.

When asked for a timeframe take your 'smooth sailing' timeframe and triple it.

This approach has proven to be remarkably accurate over the years."

If only I could get away with this!

hahaha!

bill12780

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#3

Re: Electronics Engineering Work-flow

08/27/2008 3:55 PM

Hi bill12780. You can do this!

If you look up project management in wikipedia or google you can get lots of buzzwords and learn about different ways to organize.

Frankly, I have found Deming's Plan- Do- Check- Act cycle to be a very good taxonomy for organizing anything. I successfully used it for many projects and defended it against hostile manager's who thought a pert chart or Gannt chart was the only way... as well as PHD faculty who insisted in some other bizarre orthodoxy of confusion...

Now which of your steps go in the planning box-The do box, the check box, and the ACT (revisit) box?

Plan: Recv. assignment. Get scope of assignment, get responsibilities and authorities: Yes I am authorized to use the die and tool room to make prototypes; no I am not authorized to hold up production by using their only machine on my parts when they need it for production. identify project champion. Make sure they are invested in the projects success!

Get resources/Budget. DO work on getting to understanding of assignment deliverables. Assign a tentative plan of work and time and resources needed to accomplish deliverables. Negotiate deliverables "A complete cad set of drawings checked and ready for production... " or "A working 1:10 scale model using XYZ" or .... Get it documented what your deliverable is. Then work to that.

Preliminary assessments and calculations, determine applicable specifications references materials tools to be purchased al lfeed your budget. Estimates of engineering staff time. Whos on your team? What about testing costs.

Put together calendar/ schedule of project milestones. Get agreement that dates work and no conflicts with other critical events. (annual shutdowns etc...)

Document and get the moral equivalent of a memorandum of understanding or whatever passes for that in your organization .

Do : Now that you have responsibility and authority and budget and schedule agreed to getthem formalized and published. Start work based on your plan and schedule.Gannt chart if thats how you do it. Track work time and document results and calculations. report progress to project champion. Make models, prototypes, write code whatever. Pay attention to dates, and budget, expedite materials and work, order pizza and stay up nights to get it done. Refuse informal bracket creep requests " But could it also be ruthenium plated with a beryllium rivet?"

"Hell no. Beryllium don't rivet! go away." This scope creep is very important and why you have to get that memorandum of understanding completed up front. Recognize team spirit and extraordinary work by your team.

Check: Validate models, have calculations rechecked (remember the mars lander imperial- metric units issue??? don't let that happen to you!

Send materials/assemblies to lab for validation. Test/demonstrate models, prototypes etc. collect and consider data from this step. show them off to people not on your team, ask for their feedback and comments. This can be a huge bonus. They may know recognize something that you don't know or wasn;t explained at the beginning. Listen hard!

ACT: now you have to finalize your deliverable. Take the lessons you've learned and modify the prototype, rewrite the spec s and process plans. make more of these things for "preproduction beta testing." prepare your final report, where you think you will be on the budget (acctg still hasn't cleared any of your invoices yet have they now?) and write up a Final Lesson s learned report. - about what you'd do differently next time. even if you only send to your self and your team.

You can get lots of more formal stuff out of the "project management literature" but looking at a project in 4 buckets of plan do check act should be a tool you can use and easilty administer in your company, regardless of your degree. BS degree doesn't stand for Best Supervisor...

Happy projecting!

Apologize for the length, and typos,but not the enthusism

milo

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#4

Re: Electronics Engineering Work-flow

08/27/2008 4:22 PM

I can't, nor can anyone else here, give you a full accounting of the engineering process. The amount of information on the subject could fill multiple encyclopedias.

However, what process you choose to use will greatly depend on what you intend to produce. For instance, for aviation there are a very detailed set of requirements for the design and execution processes for hardware and software.

Most every design cycle, regardless of the type of product tends to follow the "Waterfall Process". There are many others (i.e., Agile, etc.), but the Waterfall Method tends to be the most popular.

This is the product life cycle. Notice each phase tends to follow the next in a sort of downward set of stairs. For the most part each phase is discrete. That is, they are atomic, but they also depend on the successful completion of the previous phase.

In between each phase is typically a review milestone. These reviews act as gates to determine if the work product produced by each previous phase is complete and accurate before proceeding onto the next phase. I feel reviews are very important because it assures quality up front at points in the development cycle that are less costly to fix than further in the development cycle where quality costs are exponentially higher to correct.

What is not shown in the diagram above is the arrows that take you back to the start of each individual phase. These arrows would be the result of corrections or findings from a review.

The critical phases for any successful project will be:

1. Requirement specification. You must first clearly understand "What to Build".

2. The Detailed design requirements. These tell you how to build.

3. The verification phase. This answers the question of "have we built what we were supposed to build?"

As I said before, the actual details you need to now can fill reams of papers and you must consider what your industry is and tailer your design approach to your actual needs. You can spend months and months researching a process and formulating it into something that is your own and that will only be scratching the surface. The trap with this is going to be falling in love with the process and failing to produce anything useful from your department.

Before you do anything you must first document your present process in detail. You may think that you don't have one, but really do.

Next, determine where in your current process are the failures. These are the cracks in the dikes that need work first. If the current process is a shipwreck, then you may have to abandon it. However, the cost of doing that can be catastrophic.

No one like to write off the current way you do things and you will get a mountain of resistance to a large magnitude change in process. Changing the complete or even a partial process in your case is also changing your corporate culture. You need to be an agent of change to do this and it is an uphill battle that you have no idea of its magnitude.

I recommend this book for a quick read "Leading Change". It is a simple one night read and you will die without it. Get this book tonight if you can. I can't stress this enough.

Understanding how to implement change is one thing, but you also need to know what to change. This requires a detailed analysis of you present system and a collaborative effort to design a fix or replacement.

Changes must be implemented sequentially in phases so that you don't overwhelm and shut down your current work flow. You will need to spend many nights mapping out how you will implement each part of the new process and how you will measure each improvement.

You will need copious notes on everything you do. The reason is so you can measure and track improvement. Management, if it is worth its salt, will demand the data on how this translates to the following three metrics of your system:

1. Cost

2. Quality

3. Execution speed.

If you can't show a value added in these performance figure, you are a waste of money. For that matter, you will need to provide estimates for each of the above metrics before you do anything! Management must be sold on the business plan:

1. Define the problem space

2. Outline the steps and actions for process improvement

3. Provide tangible estimates of savings for the changes to the system

4. Outline the metrics you are going to use to track improvements

5. Show a process improvement plan based on data from the metrics

Think in terms of Define, Measure, Improve, Analyze, and Control.

Now that I have given you a mouthful, consider looking for a consultant to evaluate and recommend a system. You could do this yourself, but you will find that the amount of effort on your part will be a career in itself and may cost the company more than it is worth in the process with time and money. An expert can work 10X faster than you and save time and money upfront. You can still be a hero if you find a good consultant that can swiftly lead your company to a robust process that is right for you. That demonstrates your leadership ability to recognize how to apply resources to maximize time and money to get the most out of your assignment.

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#13
In reply to #4

Re: Electronics Engineering Work-flow

08/28/2008 7:55 AM

Hi Anonymous you are realy a Hero.

Very good post. This Fourm must be proud of you as you have not only given very good guidence to youngman but to even oldies like me. Jhon.Kotter's books are enlighenting on the suject. I have already read few of them in past.They have helped me in building my professional life.

Suresh Sharma.

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#16
In reply to #13

Re: Electronics Engineering Work-flow

08/28/2008 9:17 AM

Thank you for your kind words, Suresh!

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#6

Re: Electronics Engineering Work-flow

08/27/2008 6:55 PM

Milo and Hero!

WOW! Thank you so much for your time and effort!

Already I have new ideas and thoughts. I can tell that both of you have a VERY good handle on Project Management and Engineering Management.

I cant not thank you enough! I have printed these out and will refer back to them as I trudge through this.

Our company has hired a consultant (general management) the first thing he noticed was that most of the key positions were held by family members of the owners. AND that many decisions made by them were vetoed by their father.

So he recommended that we hire a CEO and that the owners retire from active participation in the day to day operations.

(like we can afford a CEO! I can get a DVM so I can take mine home! ....Sorry for bitching)

My manager is worried that the new CEO is going to come into our department and go "What the hell do you guys do here all day?"

I know that sounds bad. But we do get stuff done. The problem with "my" current process is that "I" am the only team member and there is nobody here that understands what I do and I have NO backup! (I have to order my own parts because the purchasing can't deal with it!) I was hired to replace a vendor that they have been using for 15 years! So the guy that managed that has a basic understanding but its slim at best.

I had already started to document the current work-flow but about half way through I realized that my current work-flow was basically My boss tells me what to do. I do it or get fired! We have no checks and balances here at all.

I have worked places before much more organized. But I guess I never realized the level, support, and time it takes to get to that point.

Thank you so much you to for the help! When/if I get to a point I have something short/sweet and to the point. Maybe I will send you a copy to look over. I would love to have you two critique the work and see if there is anything I can change add improve etc...

Thanks again...

Best to both of you!

bill12780

PS Milo....Your one funny dude....I laughed out loud at Beryllium Rivet! My co workers all looked at me like I was watching YouTube at work again! BUSTED! hahahah!

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#7
In reply to #6

Re: Electronics Engineering Work-flow

08/27/2008 7:59 PM

You're welcome.

I am with a trade association now with smaller family businesses (median sales $5 million) and know full well the ceo family succession authority lack of documented processes that you must be dealing with. If there is a trade association for your industry, you may find that they have some procedures already boilerplated up that you may find useful.

If you need to drop a line to me or another CR4 member, on something that you don't want to show up on google, you can always email to me (or other posters) by clicking on my name (or their name)at the top of the message.

I was impressed as well with the other postings. There are some talented and experienced folks on this forum.

milo 'beryllium don't rivet'

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#8

Re: Electronics Engineering Work-flow

08/28/2008 12:00 AM

These are all great suggestions and I wish my company would pick one and do it, but...

What to do when your company is hopelessly mired in corporate politics?

When decisions made by the "parent" company screw you and you have to take the "quality" hits?

When marketing decides to take something to a show that hasn't even been discussed at the engineering level and comes back saying they won't buy it unless it's like this?

When certain personel are allowed to do things how ever they want regardless of corporate standards?

When every time you try to do something you think is appropriate, only to be told "that's not your responsibility."

When your boss plays a game of shades and shutters and doesn't inform you of the information he has when he asks your opinion, only to find out that your answer is wrong because of his "secret" knowledge?

What do you guys think? I'm at my wits end with this crap and I'd like to know...

should I quit? I like my job and the people I work with... but our management is crap...

should I say something? If history is to be a lesson, this would lead to dismissal because we have an "executive club" that is only interested in self-preservation, if you get my meaning.

I am constantly called on by prouduction, quality, sales, service, & purchasing for help, I try my best, but at the end of the day I can't get anything done and anytime I phrase an e-mail in such a way that it is not a question (to my boss) I am reprimanded for doing something "that's not my responsibility."

but at the same time... if I opt to do nothing... I eventually get reprimanded for "not taking care of my responsibility," and wind up having to do it anyways...

It's a terribly viscious cycle of Dilbertonian Management... what can I do?

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Anonymous Poster
#12
In reply to #8

Re: Electronics Engineering Work-flow

08/28/2008 7:29 AM

God is great! he has made all humans same through out the world. I was always feeling that things are better in western countries as I belong to India. I have also experienced similar situations in corporate life and surprised to learn that world is same everywhere.

Well, it is human mind which always full with ego, superiority complex, jealousy, etc.Many a times you have a boss who is like a frog in the well doesn't know much about the outside world and keeps on trotting.Or you have a boss like a rhino who always comes attacking you,or a monkey who always plays mischief or a donkey who is lazy, or a dog who only barks. Wish you had a good boss.

Suresh Sharma.

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#17
In reply to #8

Re: Electronics Engineering Work-flow

08/28/2008 9:34 AM

Dear guest, These are issues in most organizations, it is sad to say.

I will share with you my personal internal compass, and one line of advice.

You can take it from there.

Compass:

1) Protect the customer from the organization and himself.

2) Serve the customer through Sales or Operations. (if you ain't helping make a sale or make product for dshipment, you are uneccessary)

3)Intelligently manage risk through facts and data.

4) Continuously improve the people and processes under your authority.

Advice:

You don't work for a 'company' you work for a man.

explanation: Either you two have mutual respect and he has your back and you have his, or not. There is no such thing as 'company loyalty' but when you have the support and respect of your manager, you can accomplish anything.

I worked to this compass and when the executives tried to get me to quit, then tried to eliminate my job, they found that they had a rebellion of customers, sales men, sales agents, and supervisors. Everyone knew who was getting it done for them.

If its stupid, I just made it a "B" priority and did "baby steps" while I worked on the "A" priority items according to my compass. But I made sure that they got progress reports... eventually they figured out that the stupid things were stupid and we hadn't wasted a lot of _______ on them, while the "A" items were ship shape.

Soon after, when company was bought out and reorganized and I reported to Exec. V.P., I got a Great boss who deputized me to act and commit sins rather than avoid sins, we accomplished many "impossible" things. (by this I mean it was forgiveable And preferrable to make mistakes in the course of accomplishing something (sins of commission) rather than the sin of doing nothing (sins of omission).

Literary closing:

"To thine own self be true" was Polonius' advice to his son Laertes in Hamlet.

To which I would add, "And to the customer also."

All else is bullshit.

milo

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#9

Re: Electronics Engineering Work-flow

08/28/2008 12:18 AM

You should be constantly working on the next budget even planning for 2 budgets ahead.

Forcasting your needs for new equipment, replacement, repairs, employees turn over, systems upgrades. Well planning budgets and actual budgets. By doing this you aviod that last minuite rush for a budget and those forgotten items that no one was looking for.

Take your current budget and run with it into the next 3 quarters or yearly bases.

Demand from all department list of current items that need repair or replacement. This should be a bi-weekly event.

You always working on the next budget and planning the one beyond while checking how well the current budget is working. Are there any departments who are running short or have excess funds?

Planning and checking, planning and checking constantly.

Take a night classes in Accounting, Business Operations, and business math so you can evaluate how processes are performing.

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#10

Re: Electronics Engineering Work-flow

08/28/2008 2:33 AM

Make sure you include stages for design for test, and, design for manufacture. If you've got a test engineer (department?): get their input; if you've got a production engineer (department?): get their input. Make sure you include enough prototypes for these guys to do their stuff (not just development models). Makes sure you allow the correct amount of time in the schedule for all the processes.

Above all when you produce you're plan: make sure you can justify all the steps and time constraints, and, don't let them tell you they need it quicker than the time you've proved you need. (Say OK: "Which step will we miss out or which step will we not do properly?")

When you've done it all once, and it took longer than you expected make sure you review the plan to figure out which steps took longer than expected; why, and, make sure you allow for them in the next plan.

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#11

Re: Electronics Engineering Work-flow

08/28/2008 5:03 AM

Electronics engineering articles from eClicks.co.cc

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#14

Re: Electronics Engineering Work-flow

08/28/2008 8:37 AM

Do you only work one prohect at a time?

We always were bidding other projects and setting up possible budgets incase we got the contracts.

Plus we went ober the current porjects budgets to see where we needed to imporve our estimates.

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#15

Re: Electronics Engineering Work-flow

08/28/2008 8:59 AM

Bill,

I took a project management course and I'll check my notes later and provide more feedback.

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#18

Re: Electronics Engineering Work-flow

08/28/2008 9:40 AM

Hi Bill,

I believe that presenting something you know nothing about will not only make you a complete idiot, which by your own admission you are not, but can cause a lot of damage to your reputation. Facing your boss or whomever is asking you to do the charts, and tell him I don't know how to do this, IS the way to go.

And if I read correctly between the lines, If they are looking for reasons to fire you, than just walk away from them. They are doing to you exactly what I recommended you not to do. Honesty have no price.

Just my 1 cent worth...

Wangito.

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