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Introduction and Fundamentals of Systems Engineering Prof. Amila Thibbotuwawa 1  What is a system? What is engineering? What is systems engineering? CONTENT Brief history of system...

Introduction and Fundamentals of Systems Engineering Prof. Amila Thibbotuwawa 1  What is a system? What is engineering? What is systems engineering? CONTENT Brief history of systems engineering Origins and traditional scope Evolution to broader scope Holistic view Types of processes Interdisciplinary effort Managing complexity 2  WHAT IS A SYSTEM? SYSTEM Input Process Output Elements of a SYSTEM 3 WHAT IS A SYSTEM? A system is a group of interacting or interrelated elements that act according to a set of rules to form a unified whole. A system, surrounded and influenced by its environment, is described by its boundaries, structure and purpose and expressed in its functioning. The term system comes from the Latin word systēma. Which means systematic arrangement of organisms (something having many related parts that function together as a whole). 4 SYSTEM, CONTEXT AND ENVIRONMENT Environment System Boundary System Context System Interface 5 SYSTEM, SUB-SYSTEM & COMPONENTS Electronic Toll Collection Systems Systems of System Video Clearinghouse Toll Tag Tag Reader Enforcement process System Sub Systems Sub-System Video Supplementary Camera Processor Illumination Components User Interface Enforcement Video I/O Card Panel Software Controller 6 Components  WHAT IS ENGINEERING?  Engineering involves the application of the principles of science Engineering and mathematics to solve real world problems and to innovate new products and processes across a wide range of industries and Planning, Design, Practical applications of applications. Developing, Operating, scientific knowledge, troubleshooting, integrated with: optimization of systems or process  Engineering is the use of scientific principles to design and build machines, structures, and other items, including bridges, tunnels, Management Business roads, vehicles, and buildings. Inventions are made for the society  Engineering is the creative application of science, mathematical Constrained by cost, methods, and empirical evidence to the innovation, design, For the real-world safety, regulations etc. people construction, and maintenance of structures, machines, materials, devices, systems, processes, and organizations. 7  ENGINEERING IS Identifying problems and develop solutions to complex technical issues. Designing and developing a new products, systems or solutions. Analyzing the performance of their designs and conduct tests to ensure they meet safety standards and functional requirements. Researching new technologies, materials, and processes to improve the designs and make them more efficient. Collaborating with all stakeholders. Communicating complex technical information to non-technical stakeholders. Continuously improving the designs and processes to ensure they are efficient, effective, and sustainable 8 WHAT IS SYSTEMS ENGINEERING? Systems engineering is managing complex systems by using engineering principles through their life cycle. (These systems can be anything from a computer network to a transportation system to a manufacturing plant) Solution User System Engineers & Developers System Engineering Concepts, Principals & Practices Operational need requirement 9 WHAT IS SYSTEMS ENGINEERING? Systems engineering is the process of designing and managing complex systems by using engineering and scientific principles. Systems engineering is an interdisciplinary field of engineering and engineering management that focuses on how to design, integrate, and manage complex systems over their life cycles. 10  BRIEF HISTORY OF SYSTEMS ENGINEERING While many will attribute systems thinking to great accomplishments such as the Egyptian pyramids, Incan ziggurats, the Roman aqueduct, Sigiriaya, Sri Lankan ancient irrigation system, etc. 11  BRIEF HISTORY OF SYSTEMS ENGINEERING The term systems engineering can be traced back to Bell Telephone Laboratories in the 1940s. The need to identify and manipulate the properties of a system as a whole, which in complex engineering projects may greatly differ from the sum of the parts' properties. U. S. military systems were initial main focuses. The continuing evolution of systems engineering comprises the development and identification of new methods and modeling techniques. Popular tools that are often used in the systems engineering context were developed during these times, including USL (Universal Systems Language), UML (Unified Modeling Language), QFD (Quality Function Deployment), and IDEF (ICAM Definition later Integration Definition). 12  BRIEF HISTORY OF SYSTEMS ENGINEERING In 1990, a professional society for systems engineering, the National Council on Systems Engineering (NCOSE), was founded by representatives from a number of U.S. corporations and organizations. NCOSE was created to address the need for improvements in systems engineering practices and education. organization was changed to the International Council on Systems Engineering (INCOSE) in 1995 for moving into the global context. 13  CONCEPT Systems engineering signifies only an approach and, more recently, a discipline in engineering. The aim of education in systems engineering is to formalize various approaches simply and in doing so, identify new methods and research opportunities similar to that which occurs in other fields of engineering. As an approach, systems engineering is holistic and interdisciplinary in flavour. 14  Environment Provided to Customer Interacts Provides Elicits Needs Needs System Process Specifies System Engineer Implements System Engineering focuses on ensuring the pieces work together to achieve the objectives of the whole 15 Development Team ORIGINS AND TRADITIONAL SCOPE  The traditional scope of engineering embraces the conception, design, development, production and operation of physical systems.  Systems engineering, as originally conceived, falls within this scope. "Systems engineering", in this sense of the term, refers to the building of engineering concepts. 16 EVOLUTION TO BROADER SCOPE The use of the term "systems engineer" has evolved over time to embrace a wider, more holistic concept of "systems" and of engineering processes. This evolution of the definition has been a subject of ongoing controversy, and the term continues to apply to both the narrower and broader scope. 17 EVOLUTION TO BROADER SCOPE Traditional systems engineering was seen as a branch of engineering in the classical sense, that is, as applied only to physical systems, such as spacecraft and aircraft. Currently, systems engineering has evolved to take on a broader meaning especially when humans were seen as an essential component of a system. 18  EVOLUTION TO BROADER SCOPE - SEBOK  Consistent with the broader scope of systems engineering, the Systems Engineering Body of Knowledge (SEBoK) has defined three types of systems engineering: 1) Product Systems Engineering (PSE) is the traditional systems engineering focused on the design of physical systems consisting of hardware and software. 2) Enterprise Systems Engineering (ESE) pertains to the view of enterprises, that is, organizations or combinations of organizations, as systems. 3) Service Systems Engineering (SSE) has to do with the engineering of service systems. A service system as a system which is conceived as serving another system. Most civil infrastructure systems are service systems. 19 HOLISTIC VIEW Systems engineering focuses on analyzing and eliciting customer needs and required functionality early in the development cycle, documenting requirements. Then proceeding with design synthesis and system validation while considering the complete problem in the system lifecycle. This includes fully understanding all of the stakeholders involved. 20  TYPES OF PROCESSES  The systems engineering process can be decomposed into A Systems Engineering Technical Process  The Technical Process includes assessing available information, defining effectiveness measures, to create a behavior model, create a structure model, perform trade-off analysis, and create sequential build & test plan. A Systems Engineering Management Process.  The goal of the Management Process is to organize the technical effort in the lifecycle. Depending on their application, there are several models that are used in the industry, all of them aim to identify the relation between the various stages mentioned above and incorporate feedback. Examples: Waterfall model, Fish Bone, Iterative development, V-model etc. 21 GROUP WORK: SYSTEMS CLASSIFICATION Natural Systems vs Man-Made Systems Static Systems vs Dynamic Systems Conceptual Systems vs Physical Systems Open Systems vs Closed Systems 22  GROUP ASSIGNMENT  Natural vs Man-Made Systems: Scenario: Compare and contrast the logistics system of a city (Man-Made) with the ecological system of a nearby forest (Natural). Topic: Environmental impact and sustainability in logistics.  Static vs Dynamic Systems: Scenario: Analyze the inventory management system of an online retailer during a Black Friday sale (Dynamic) vs a regular business day (Static). Topic: Adaptability and responsiveness in logistics.  Conceptual vs Physical Systems: Scenario: Examine the conceptual design of an autonomous drone delivery system for a logistics company and compare it to the physical implementation. Topic: Integration of conceptual and physical elements in logistics.  Open vs Closed Systems: Scenario: Evaluate the logistics network of a global supply chain (Open) vs a small local warehouse (Closed). Topic: Connectivity and autonomy in logistics networks. 23  NATURAL SYSTEMS VS MAN-MADE SYSTEMS  Natural systems have defined Laws (laws of thermodynamics and gravity), and all components of a natural system are fundamental to survival.  A natural system is a self-organized system that nature formed after millions of millions of years’ selection and development.  Examples of natural systems are the planet, oceans, and natural lakes. A natural system sustains itself by self organizing to a state of equilibrium. For example, the food chain in a natural lake.  Any disturbance to this equilibrium can be devastating for the natural system. 24  NATURAL SYSTEMS VS MAN-MADE SYSTEMS  Man-made systems are made by humans. Man-made systems, such as computers, road, building or automobiles, etc. such as cannot be obtained from nature, but only through the creative efforts of humans.  The systems engineering studies man-made systems as objects, with less concern for natural systems.  Man-made systems can be divided into Engineered Systems and Non-engineered Human Systems (legal, monetary, etc.).  Man-made systems are more unpredictable and involve nonessential components like social media, marketing and recreation. 25  STATIC SYSTEMS VS DYNAMIC SYSTEMS  Static systems are those structural systems that do not change their state within a specified system life cycle, such as a bridge, a building, or a highway.  The distinction between static and dynamic systems is relative, not absolute.  The systems engineering studies man-made systems as objects, with less concern for natural systems.  Depending on the different perspectives from which a system is being analyzed, a system may be considered static or dynamic. The context of systems engineering, we treat some fixtures or structures as static.  Man-made systems are more unpredictable and involve nonessential components like social media, marketing and recreation. 26 STATIC SYSTEMS VS DYNAMIC SYSTEMS  A dynamic system is one where its state, or the state of its components, changes over time, either in a continuous or discrete manner.  A dynamic system’s state can be considered a function of time, its change taking place at either a more deterministic rate or a more stochastic rate.  Examples are airport, vehicle, material flows and human activities to investigate the effectiveness of production management, etc. 27  CONCEPTUAL SYSTEMS VS PHYSICAL SYSTEMS  Conceptual systems are those consisting only of concepts, not real objects, so we cannot visually see or physically touch these systems.  Conceptual systems illustrate the relationships among objects and allow us to understand the system and communicate details about the system’s structures and mechanism.  A simulation model of a factory operation process, a blueprint of the machine assembly, or the information processing model of human cognition and perception would be examples of conceptual systems.  Before the actual physical systems are manufactured, parts procured, and systems assembled, a conceptual model is usually built first to allow us to analyze the feasibility of such a system and assess the fundamental characteristics of system performance.  Conceptual systems design is a very critical step for systems engineering design. 28  CONCEPTUAL SYSTEMS VS PHYSICAL SYSTEMS  Our world comprises physical systems, and physical systems consist of objects that can be seen, touched, and felt.  Most of the natural systems such as animals, bacteria, lakes, and humans are all physical systems; physical systems also include most of the man-made systems, such as the computers, appliances, tools, and equipment that we humans use on a daily basis. 29  OPEN SYSTEMS VS CLOSED SYSTEMS  Systems can be classified based on their interaction with the environment.  Open systems exchange information, matter, or energy with their surrounding environments.  Any system can be more or less considered an open system.  In systems engineering, a system is considered open—especially when one takes a life cycle perspective—if the system interacts with the environment and its impact on the environment is one of competitive advantage that system design should include in the early development stages. 30  OPEN SYSTEMS VS CLOSED SYSTEMS  Closed systems do not exchange things such things information, matter, or energy with their surrounding environments.  In a very strict sense, there is no absolutely closed system existing in the universe, while any system can be more or less considered an open system.  In Genaral, systems are thought of as closed systems when the exchange of matter, information, or energy can be ignored.  In physics, closed systems are further classified as closed systems or isolated systems. An isolated system has no exchange of anything with the outside environment, but when only energy is exchanged, the system is closed but not isolated.  Closed systems can be found in our daily life, such as a sealed container of water or gas.  In thermodynamics, the laws of thermodynamics requires the system to be classified exactly as isolated, closed, or open. 31 32 INTERDISCIPLINARY EFFORT https://www.britannica.com/technology/airport/Passenger-terminal-layout-and-design 33  INTERDISCIPLINARY EFFORT System development often requires contribution from diverse technical disciplines. By providing a systems view of the development effort, systems engineering helps mold all the technical contributors into a unified team effort, forming a structured development process That proceeds from concept to production to operation and, in some cases, to termination and disposal. In an acquisition, the holistic integrative discipline combines contributions and balances tradeoffs among cost, schedule, and performance while maintaining an acceptable level of risk covering the entire life cycle of the item. 34 INTERDISCIPLINARY EFFORT 35 INTERDISCIPLINARY EFFORT The Science Domain The Engineering Domain The Management Domain Systems Engineering The Art Domain Supporting Roles 36 MANAGING COMPLEXITY 37 MANAGING COMPLEXITY The need for systems engineering arose with the increase in complexity of systems and projects, in turn exponentially increasing the possibility of component friction, and therefore the unreliability of the design. At the same time, a system can become more complex due to an increase in size as well as with an increase in the amount operations and variables that are involved in the design. Systems engineering encourages the use of tools and methods to better comprehend and manage complexity in systems. Some examples of these tools; System architecture, System model, Modeling, and Simulation, Optimization, System dynamics, Systems analysis, Statistical analysis, Reliability analysis, Decision making, etc. 38  MANAGING COMPLEXITY Alali, Baqer and Ariel Pinto. “Project, systems and risk management processes interactions.” PICMET '09 - 2009 Portland International Conference on Management of Engineering & Technology (2009): 1377-1386. https://en.wikipedia.org/wiki/File:SE_Activities.jpg 39 40  Fundamentals of Systems Engineering - Interfaces Prof. Amila Thibbotuwawa What we know so far… ▪ System, Engineering, and Systems Engineering ▪ History ▪ Traditional scope to broader scope ▪ Types of processes ▪ Interdisciplinary effort ▪ Systems engineering viewpoint ▪ Successful system, best system and balance system ▪ Systems domains ▪ System hierarchies ▪ System environment ▪ System context ▪ Context diagram 2  Activity ▪ Form a small group with 4-5 members ▪ Identify external entities that interact with bus management system. ▪ Draw a context diagram for the bus management system ▪ Present your findings 3 Content ▪ Interfaces ▪ Stakeholders and users ▪ System lifecycle 4 How they communicate / interact 5  Interface ▪ To connect two or more elements for the purpose of passing information from one to the other. ▪ It can be between – systems, subsystems, components, subcomponents or parts 6 Types of interface ▪ Connector ▪ Converter ▪ Isolator 7  Connector interface ▪ Connector interface allows to transfer forces, energy, data, signals or materials. ▪ Connector interfaces are used to connect devices to exchange information and signals ▪ Can be attached to various devices, such as car navigation systems, car audio systems, and PC peripherals to provide power and input and output audio and video signal data 8  Converter interface ▪ The converter interface alters or transforms (or interprets) the form to another form. 9  Isolator interface (control or suppress) ▪ Isolator interface controls or suppress forces, energy, data, signals or materials ▪ An isolator is a mechanical switching device that isolates a circuit or equipment from a power source ▪ Isolate a faulty section from a healthy section to avoid severe faults 10 11  Standardized interfaces ▪ Make systems more compatible with each others, we often reach consensus as a community that standardizes the interface. ▪ These standards are controlled and managed by third party standardization or consortium organizations. ▪ Common interfaces among components. ▪ Foster interchangeability. ▪ Ease of maintenance and upgrade. ▪ Decreases a system’s total lifecycle cost.  Standardized interfaces ▪ Examples: ▪ Computer: USB, USB-C, SATA, PCI, VGA, AGP, HDMI, S-Video, DVI, DDR, DDR2/3,4, RJ45, PS2, Parallel Port, Serial Port, etc. ▪ Vehicle : Seat belt, hardware (nuts and bolts), tire sizes (P225/55R1691S), wheel lug, electrical plugs, tire air valve, battery, towbar, OBD, etc. ▪ House: Bulb (B22, E26, E27), plug, switch, Door locks, tap, commode, padlocks, door hinges, roof tile, roofing sheets, MCB, RCCB, Wi-Fi routers, etc.  Interface management ▪ Interface management is a crucial aspect of system development. ▪ It is one of the most important part of the integration management. ▪ Systems Engineers are responsible for ✓ ensuring interfaces are defined and identified ✓ reduce or eliminate incompatibilities between the different interfaces ✓ coordinate and control interfaces ✓ maintain system integrity through a system’s life ▪ Has to predict future changes and select most suitable interfaces  Activity ▪ Form a small group with 3-4 members. ▪ Identify a transport and logistics domain related system. ▪ Identify different types of interfaces (connector, isolator, converter) in that system. ▪ Present your findings. 15  Stakeholders The success of a product or service is determined by the developer’s ability to capture and translate user or stakeholder requirements into a solution that fulfils those requirements. Stakeholders are people or groups with an interest in the success of a business or project. https://alicebrazao.com/stakeholder-theory-overview/ 16  Users ▪ An individual or group that interacts with the system or benefits from the system during its utilization. ▪ Direct users - who use the system themselves ▪ Indirect users - who ask other people to use the system on their behalf ▪ Remote users - who do not use the system, but depend on the output ▪ Support users - who ensure that the system works for others, such as direct users. ▪ All users are stakeholders. But not all stakeholders are users. 17 18 Stakeholders, Customers and Users 19 Activity ▪ Form a small group with 3-4 members. ▪ Imagine your team was appointed as the systems engineering consultancy team for the Western Province bus management software system development project. ▪ To identify the exact requirements, you have to consult stakeholders. ▪ Categorized the stakeholders into customers, users, and general stakeholders and make a Venn diagram. ▪ Present your findings. 20 21 Fundamentals of Systems Engineering Prof. Amila Thibbotuwawa  Systems Thinking Hard, Soft and Critical Systems Thinking Perspectives of Systems Engineering Systems engineering viewpoint Successful system The best system A balance system CONTENT System hierarchies System environment System context Context diagram Systems Thinking Systems thinking is an interdisciplinary approach to understanding and analyzing complex systems. It focuses on examining the relationships, interactions, and dynamics within a system as a whole, rather than isolating individual components or elements. Systems thinking recognizes that a system is more than just the sum of its parts and that its behavior and properties emerge from the interactions and interdependencies among its components.  Systems Thinking Holistic Perspective Multiple Perspectives Key principles of Interconnections & systems thinking Relationships include Emergence & Nonlinearity Feedback Loops Types of Systems Thinking System Thinking Hard System Soft System Critical System Thinking Thinking Thinking 5  Hard Systems Thinking  Hard systems thinking emphasizes the application of systems thinking principles to problem-solving in tangible and well- defined situations.  It focuses on the design and optimization of systems with clear objectives and measurable outcomes.  Hard systems thinking often employs mathematical models, simulations, and quantitative analysis to understand and optimize system behavior.  It is commonly used in engineering, operations research, and management science. 6 Soft Systems Thinking  Soft systems thinking is concerned with addressing complex and ill- defined problems involving human and social systems.  It recognizes the subjective and qualitative aspects of systems and emphasizes understanding the perspectives, values, and mental models of different stakeholders.  Soft systems thinking often involves engaging stakeholders in the process of problem definition, modeling, and decision-making.  It emphasizes qualitative methods such as interviews, group discussions, and concept mapping to explore and represent multiple viewpoints.  Soft systems thinking is commonly applied in fields like organizational development, policy analysis, and social sciences. 7  Critical Systems Thinking  Critical systems thinking goes beyond problem-solving and aims to critically examine and challenge underlying assumptions, values, and power structures within systems.  It focuses on understanding the broader social, political, and ethical implications of systems and interventions.  Critical systems thinking incorporates perspectives from critical theory and social sciences to analyze and critique the systemic issues and their impact on various stakeholders.  It aims to promote social justice, equity, and sustainability.  Critical systems thinking is often used in fields such as social and environmental justice, sustainable development, and participatory decision-making processes. 8  Perspectives of Systems Engineering Systems Thinking Systematic Systemic thinking System-as- Closed- Dynamic Forest Operationa Quantitativ Scientific cause loop Analysis Synthesis thinking thinking l thinking e thinking thinking thinking thinking 9  Systemic Thinking  Systemic thinking refers to a way of understanding and analyzing complex systems by considering the interconnections, relationships, and dynamics among their components.  Systemic thinking has three steps (Ackoff 1991):  A thing to be understood is conceptualized as a part of one or more larger wholes, not as a whole to be taken apart.  An understanding of the larger system is sought.  The system to be understood is explained in terms of its role or function in the containing system. 10 Systemic Thinking - Viewpoints 1. Dynamic thinking: which frames a problem in terms of a pattern of behaviour over time. 2. System-as-cause thinking: which places responsibility for a behaviour on internal factors who manage the policies and plumbing of the system. 3. Forest thinking: which is believing that to know something you must understand the context of relationships. 4. Operational thinking: which concentrates on getting at causality and understanding how behaviour is actually generated. 5. Closed-loop thinking which views causality as an ongoing process, not a one-time event. With the effect of feeding back to influence the causes, and the causes affecting each other. 6. Quantitative thinking: which accepts that you can always quantify something even though you can’t always measure it. 7. Scientific thinking: which recognizes that all models are working hypotheses that always have limited applicability. 11 Systematic thinking  Systematic thinking refers to a cognitive process that involves analyzing and solving problems in a methodical and organized manner.  It is a structured approach to thinking that aims to identify patterns, relationships, and logical sequences in order to gain a comprehensive understanding of a problem or situation. 1. Analysis: breaking a complex topic into several smaller topics and thinking about each of the smaller topics. Analysis can be considered as a top-down approach to thinking about something (Descartes 1637, 1965). It has been termed reductionism because it is often used to reduce a complex topic to a number of smaller and simpler topics. 2. Synthesis: combining two or more entities to form a more complex entity. Synthesis can be considered as a bottom- up approach to thinking about something. 12 Systems engineering viewpoint  Systems engineering was initially filled by engineers and scientists who acquired through experience the ability to lead successfully complex system development programs.  To do so, they had to acquire a greater breadth of technical knowledge and, more importantly, to develop a different way of thinking about engineering, which has been called “the systems engineering viewpoint.”  The essence of the systems engineering viewpoint is exactly what it implies—making the central objective the system as a whole and the success of its mission.  The systems engineering viewpoint must include a combination of risk taking and risk mitigation. 14  Successful system  The principal focus of systems engineering, from the very start of a system development, is the success of the system—in meeting its requirements and development objectives, its successful operation in the field, and a long, useful operating life.  It aims at the establishment of a technical approach that will both facilitate the system’s operational maintenance and accommodate the eventual upgrading that will likely be required at some point in the future.  It attempts to anticipate developmental problems and to resolve them as early as possible in the development cycle; where this is not practicable, it establishes contingency plans for later implementation as required. 15  The “best” system  Systems engineering does seek the best possible system, which, however, is often not the one that provides the best performance.  The popular maxims use the terms “best” and “good enough” to refer to system performance.  However, systems engineering views performance as only one of several critical attributes; equally important ones are affordability, timely availability to the user, ease of maintenance, and adherence to an agreed-upon development completion schedule.  The systems engineer seeks the best balance of the critical system attribute from the standpoint of the success of the development program and of the value of the system to the user. 16  The “best” system  The interdependence of performance and cost can be understood in terms of the law of diminishing returns.  Assuming a particular technical approach to the achievement of a given performance attribute of a system under development, the figure is a plot of a typical variation in the level of performance of a hypothetical system component as a function of the cost of the expended development effort. Kossiakoff, A., Biemer, S. M., Seymour, S. J., & Flanigan, D. A. (2020). Systems engineering principles and practice. John Wiley & Sons. 17  A balanced system  “a harmonious or satisfying arrangement or proportion of parts or elements, as in a design or a composition.”  An essential function of systems engineering is to bring about a balance among the various components of the system.  Designed by engineering specialists, each intent on optimizing the characteristics of a particular component. 18  A balanced viewpoint  A system balanced view means a focus on balance, ensuring that no system attribute is allowed to grow at the expense of an equally important or more important attribute.  For example, greater performance at the expense of acceptable cost, high speed at the expense of adequate range, or high throughput at the expense of excessive errors.  Virtually all critical attributes are interdependent, a proper balance must be struck in essentially all system design decisions.  The judgment of how they should be balanced must come from a deep understanding of how the system works. 19 A balanced viewpoint Kossiakoff, A., Biemer, S. M., Seymour, S. J., & Flanigan, D. A. (2020). Systems engineering principles and practice. John Wiley & Sons. 20 Perspectives of systems engineering  The field of systems engineering has matured rapidly in the past few decades  There will continue to exist a variety of differing perspectives as more is learned about the potential and the utility of systems approaches to solve the increasing complex problems around the world.  A perspective that relates a progression in the maturity of thinking includes concepts of systems thinking, systems engineering, and engineering systems. 21 Comparison of systems perspectives System Thinking System Engineering Engineering System Focus on process Focus on whole product Focus on both process and product Consideration of issues Solve complex technical problems Solve complex interdisciplinary technical, social, and management issues Evaluation of multiple factors and Develop and test tangible system Influence policy, process and use influences solution systems engineering to develop system solutions Inclusion of patterns, Need to meet requirements, Integrate human and technical relationships, and common measure outcomes and solve domain dynamics and understanding problems approaches Kossiakoff, A., Biemer, S. M., Seymour, S. J., & Flanigan, D. A. (2020). Systems engineering principles and practice. John Wiley & Sons. 22 Comparison of systems perspectives  The systems engineering approach tends to be more technical, seeking from potential future users and developers of the solution system, what are the top-level needs, requirements, and concepts of operations, before conducting a functional and physical design, development of design specifications, production, and testing of a system solution for the problem.  Attention is given to the subsystem interfaces and the need for viable and tangible results.  A broader and robust perspective to systems approaches to solve very extensive complex engineering problems by integrating engineering, management, and social science approaches using advanced modeling methodologies is termed “engineering systems.” 23  Systems domains Kossiakoff, A., Biemer, S. M., Seymour, S. J., & Flanigan, D. A. (2020). Systems engineering principles and practice. John Wiley & Sons. 24 Knowledge domains Systems System Engineer Subsystems Signals Data Materials Energy Components Electronic Electro-optical Software Electromechanical Mechanical Thermomechanical Subcomponents Design specialist Parts Kossiakoff, A., Biemer, S. M., Seymour, S. J., & Flanigan, D. A. (2020). Systems engineering principles and practice. John Wiley & Sons. 25  System Hierarchy  Organizational representation of a system structure using partitioning relationships (by International Organization for Standardization).  Partitioning is displayed as a set of elements within a system, focusing on the relationships of those elements to the next higher order element, while not focusing on the details for how those elements interact or interface with each other. 26 27 28 29 30  Steps  Start with the system at the top (Level 1).  Level 2 should be the primary subsystems.  Level 3 are the components that make up each of the subsystems.  Level 4 are the inner subcomponents within each component.  Typically, there is no need to decompose your system down to the part level (nuts, bolts & brackets).  The level of decomposition depends on the complexity of your system.  Level 3 is a good rule of thumb for systems engineering. 31  Group Activity Identify subsystems for an automated teller machine (ATM). Identify components for each subsystems. Developed system hierarchy for ATM and present your findings 33 34 Context dependent  An ATM can be the system in one hierarchy with computer as a subsystem.  A computer can be the system in another context.  Or ATM can be a subsystem of the banking system. 35 Domain specific Physical hierarchy Behavior hierarchy Requirements hierarchy Organizational hierarchy 36 How far to decompose?  Until you can hand off the object to design engineer  Until you know you can make or buy the object  Typically, the design engineers will figure out what the smaller piece parts will be inside of each of these elements 37  System Environment  System environment is a context determining the setting and circumstances of all interactions and influences with the system of interest.  External entities that the system interacts with in a specified context.  Sometimes, it is called as system context. 38 System, Context and Environment  Context = System Context  Environment = Internal Environment + External Environment Environment System Boundary System Context System Interface 39 System context and environment https://www.geospatialworld.net/blogs/what-is-intelligent-transport-system-and-how-it-works/ 40 System boundaries  The limits that determine if an entity is a part of the system and is under the systems engineer’s control or if the entity is a part of the operating environment and is not under the systems engineer’s control.  It is within the system boundaries:  The organization has control over the entity’s behaviours, development, requirements and funding.  The organization has operational control of the entity after deployment. 41  System context diagram  System context diagram usually called as context diagram.  Context diagrams show the interactions between a system and other actors (external factors/entities/system) with which the system is designed to interface.  In other wording, context diagram defines the boundary between the system, or part of a system, and system environment (context), showing the entities that interact with it.  System context diagrams show a system, as a whole and its inputs and outputs from/to external factors. 42  System context diagram  This diagram is a high-level view of a system.  System context diagrams can be helpful in understanding the context which the system will be part of.  Usually, users are considered as external entities. However, system engineer can decide either they are internal or external entities. 43 How to build a context diagram  Identify the context (mission and environment)  Identify and list all entities in the context  For each entity, determine if it is in or out of the system boundaries  Place the system at the center of the diagram  Surround the system with the external entities  Create connection between external entities and the system  Determine the kind of interactions that take place  Determine owner of each interaction (external entities or the system) 44 45 Group Activity  Form a small group with 8-10 members  Identify external entities that interact with bus management system.  Draw a context diagram for the bus management system  Present your findings Thank You 47 System lifecycle Prof. Amila Thibbotuwawa Production and manufacturing vs project Production is the process of converting resources into finished products. Manufacturing is the process where machines produce goods from raw materials. A project is a set of tasks that must be completed in order to arrive at a particular goal or outcome within a specific time. 2 Production The production process involves a series of activities that add value to the inputs through a combination of human effort, machinery, and technology. The ultimate goal of production is to create products that meet the needs of consumer. Generate profit for the producer. Input can be tangible or intangible. Output can be goods or service (tangible and intangible) 3 5 Manufacturing Mainly men and machines are used Output is goods only (tangible) Capital intensive High uniformity of outputs 6 7 Production vs Manufacturing Attributes Production Manufacturing It’s a process of manufacturing It’s a process of making final finished products with the help of Definition products using natural resources for machines, workforce, chemicals and satisfying human needs. biological processes. Raw materials are owned by the The company procures raw Conceptual meaning organization and are ultimately materials and processes them to get processed to get output. finished goods. Production The output can be both goods and Finished products The output is only goods. services. Production processes can be both Manufacturing processes are only Nature of Inputs tangible and intangible. tangible. Production creates utilitarian Manufacturing creates products Result products that can be used that are ready to be sold in the immediately or later. market. Manufacturing Manufacturing requires machines, Mandatory Machines may or may not be an efficient workforce, and big requirements required for production. manufacturing setup. Production is a superset of Manufacturing is a subset of Subcategory manufacturing. production. Production is basically concerned Manufacturing is the conversion of Process requirement with the conversion of inputs into a raw materials into finished products. utilitarian output. 8 Project Project has a start date and end date (temporary) Project produces a unique outcome Project has specific objectives Project has limited resources Project has risk(s). It has uncertainty. 9 10  System lifecycle (non-projects) ▪ The system lifecycle is a view of a system or proposed system that addresses all phases of its existence to include system conception. 11 System lifecycle (projects) 12 System lifecycle (software) 13  Requirement gathering Quick design Incorporate customer suggestion Build prototype Not satisfied Customer evaluation and acceptance the prototype Satisfied Design Implementation Testing Maintenance The Concept Phase 16 The concept phase ▪ Sometime called as concept development phase. ▪ It is one of the most important phase. ▪ Its primary purpose is to figure out exactly what product or system should be developed. 1. Identify need / problem space 2. Explore preliminary concepts 3. Select and define concept - Development of System Requirement Specification (SRS) https://www.behance.net/gallery/14924611/Car-Drawing-Techniques 17 The concept phase ▪ Typically begins with the recognition that some form of product or system is required to meet some form of need. ▪ It can be identified either within organization or marketplace. ▪ Or other organizations would ask you to solve a need they have. ▪ Most of the work is systems engineer performs is done in the concept stage. ▪ S/he will lead and guide the team and identify the need and potential solutions. ▪ With retaining the return of investment. 18 The concept The main objective of the systems engineer is to reduce the risk. phase The concepts exist as computer models or documentation or simple 3D models. Cost of rework is significantly cheaper in the concept phase. Explore various alternatives by trade studies or other Multi-criteria decision- making (MCDM) technique. A Trade Study is a study that identifies a preferred solution among a list of qualified solutions. The trade study will examine these solutions against criteria such as; cost, schedule, performance, weight, system configuration, complexity, the use of Commercial off-the-Shelf (COTS), and many others. 19 The concept phase ▪ Define the problem ▪ Define boundaries ▪ Selecting a most suitable solution among alternatives (AOA – Analysis of alternative) ✓ Calculations, mathematical models, simulations, prototypes, mockups ▪ Documenting potential solutions ▪ Capture further requirements ▪ Estimate cost, schedule, lifecycle cost ▪ Develop operational concept (OpsCon) ▪ Understand the level of risk ▪ Development strategy 20 The concept phase – Outputs ▪ Architecture 21 The concept phase – Outputs ▪ Prototypes 22 The concept phase – Outputs ▪ Concept models 23 The concept phase – Outputs ▪ Architecture ▪ Prototypes ▪ Concept models ▪ Cost, schedule, total lifecycle cost estimates ▪ Return of Investment of business case ▪ Develop operational concept (OpsCon) ▪ System requirement specification (SRS) ▪ Development specifications 24 The concept phase – biggest mistake ▪ Organization, leaders, sponsors and stakeholders need to move quickly into the development stage with tangible outcomes than concepts. Never skip the concept stage ! 25 System development phase 26 System lifecycle (non-projects) 27 Architecture Prototypes Concept models Cost, schedule, total lifecycle cost estimates Return of Investment of business case Develop operational concept (OpsCon) System requirement specification (SRS) Development specifications 27 System development Create a system detailed Refine requirements design Develop and build up the Conduct verification system testing 29  Development Refined requirements phase outputs Refined architecture Test articles Cost and schedule estimates ROI business case updated Production specifications 30 Production phase 31 System lifecycle (non-projects) 32 The production stage Conduct validation testing Set up and refine production line Integrate design changes Begin deploying system 33 Production phase outputs Produced systems Updated design/ architecture Test results Product manuals Initial support infrastructure (repair facilites, spare parts, logistics, etc.) 34 Utilization phase System lifecycle (non-projects) 36  The system is deployed and used Utilization intended operational environment phase Discrepancies are discovered by users Enhancements and upgrades are integrated 37 Support Phase 38 System lifecycle (non-projects) 39 Support phase The system is maintained. The system is repaired during the breakdown. Modification or updates may be incorporated to improve maintenance, cost, service life, etc. 40 Retirement phase 41 System lifecycle (non-projects) 42 Retirement phase ▪ Systems are prepared and disposed of ▪ Infrastructure is shutdown or re-aligned to other systems ▪ Has to recycle, reuse, deposal, etc. The final stage in the product life cycle is the retirement stage. It ensures that the system, in addition to its related operational, production and support services, are removed safely. 43 44 MAINTENANCE SYSTEMS ENGINEERING Prof. Amila Thibbotuwawa Management takes over the larger picture while maintenance keeps everything running smoothly on a daily basis.  Definition: A formal definition of maintenance is “that function of manufacturing management that is concerned with day-to-day problem of keeping the physical plant in good operating condition” Unlocking the Power of Maintenance Systems Engineering in Industry Maintenance - Group work 01 Select a Company and make discuss covering the following.  What is maintenance?  What is maintenance systems engineering?  What are the objectives of maintenance systems engineering?  Explain with examples.  Objectives of Maintenance What are the objectives of MSE?  Objectives: Keep productive Minimize loss of Minimize repair assets in Condition productive time time & cost working Minimize total Minimize Improve quality maintenance accidents of products cost  Dependability of service Assured quality Importance: Prevent equipment failure Cost control Huge investment in equipment  Areas of Maintenance: 1. Civil maintenance- Building construction and maintenance, maintaining service facilities 2. Mechanical Maintenance- Maintaining machines and equipments, transport vehicles, compressors and furnaces. 3. Electrical Maintenance- Maintaining electrical equipments such as generators, transformer, motors, telephone systems, lighting, fans, etc.  Types of Maintenance What are the different types of Maintenance? ORGANISATION MAY USE ANY OR ALL THE FIVE TYPES OF MAINTENANCE Breakdown maintenance or corrective maintenance Preventive maintenance Predictive maintenance Routine maintenance Planned maintenance BREAKDOWN MAINTENANCE Occurs when there is a work stoppage due to machine breakdown Maintenance becomes repair work Seeks to get the equipment back into operation as quickly as possible To control the investment in replacement spare machines.  Preventive Maintenance? What is preventive maintenance? What is predictive maintenance? What are the preventive actions? What are the predictive actions? Explain with examples  Preventive management It is undertaken before the need arises and aims to minimize the possibility of unanticipated production interruption or major breakdowns.  Predictive maintenance Vibration analyzers Amplitude meters Audio gauges Optical tooling Resistance gauges Conditions can be measured on a continuous basis, and this enables the maintenance people to plan for an overhaul. Difference between the two Preventive and Predictive? The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses monitoring the condition of machines or equipment to determine the actual mean time to failure whereas preventive maintenance depends on industrial average life statistics.  Routine maintenance Includes activities such as Periodic inspection  Cleaning  Lubrication  Repair of production equipment after their service life.  Planned maintenance:  It involves the inspection of all plant and equipment, machinery, buildings according to a predetermined schedule in order to service overhaul, lubricate or repair, before actual break down or deterioration in service occurs.  Opportunistic Maintenance In multi component system, several failing components, often it is advantageous to follow opportunistic maintenance. When an equipment or system is taken down for maintenance of one or few worn out component, the opportunistic maintenance can utilize for maintaining or changing other wear out components, even though they are not failed. It is not a specific maintenance system, but its a system of utilizing an opportunity which may come up any time.  Corrective Maintenance Maintaining action for correcting or restoring failed unit. Very vast scope for small actions like adjustment, minor repairs to redesign of types of equipment Generally, once taken and completed fully Usually carried out in four steps : 1st step : collection of data, information and Analysis 2nd step : identifying the causes 3rd step : find out the best possible solution to illuminate likely causes 4th step : Implement those solutions  Other different types Emergency maintenance: It is carried out as fast as possible to bring a failed machine or facility to a safe and operationally efficient condition. Routine maintenance which includes those maintenance activities that are repetitive and periodic in nature such as lubrication, cleaning, and small adjustment. Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running, and they represent those activities that are performed before the actual preventive maintenance activities take place. Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.  Other different types Window maintenance Which is a set of activities that are carried out when a machine or equipment is not required for a definite period. Shutdown preventive maintenance Which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation. Remedial maintenance Which is a set of activities that are performed to eliminate the source of failure without interrupting the continuity of the production process. Deferred maintenance Which is a set of corrective maintenance activities that are not immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process. Maintenance strategy continuum The physical to digital to physical loop Trade-offs of the different types of maintenance The characteristics of a digital supply network The technologies that drive PdM Shutdown corrective maintenance which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation. Design-out maintenance which is a set of activities that are used to eliminate the cause of maintenance, simplify maintenance tasks, or raise machine performance from the maintenance point of view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure and their long-term repair or replacement cost is very expensive. Engineering services which includes construction and construction modification, removal and installation, and rearrangement of facilities. Shutdown improvement maintenance which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation. Predictive maintenance is a set of activities that detect changes in the physical condition of equipment (signs of failure) to carry out the appropriate maintenance work for maximizing the service life of equipment without increasing the risk of failure. It is classified into two kinds according to the methods of detecting the signs of failure: – Condition-based predictive maintenance – Statistical-based predictive maintenance Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs of failure. Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components to develop models for predicting failures. The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the information. Some researchers classified predictive maintenance as a type of preventive maintenance.  CONTROL OF MAINTENANCE Authorized by an official Maintenance schedule Issue materials against proper authorization Maintenance budgets Equipment records  Issues: how much maintenance is needed? What size maintenance crews must be used? Can maintenance be sub-contracted? Should maintenance staff be covered by wage incentive schemes? Can effective use be made of computers for analyzing and scheduling activities?  Preventive Maintenance Preventive maintenance is undertaken before the need arises and aims to minimize the possibility of un-anticipated production interruptions or major breakdowns. It consists of:  Proper design and installation of equipment  Periodic inspection of plant and other equipment  Repetitive servicing and overhaul of equipment  Adequate lubrication, cleaning and painting  Benefits Greater Safety Decreased Production Down Time Fewer large Scale & Repetitive Repairs Less Cost for Simple Repairs Less Standby Equipment Required Better Spare parts Control Proper Identification f Items Maintenance Scheduling: Importance of scheduling: Facilitates optimum use of highly paid maintenance Scheduling refers to timing and sequences of operations. staff It is an important segment of the production planning & Equipments can be utilized effectively control activity as well as the service operations like plant maintenance Eliminates undue interruptions in the production flow Eliminates chances of sudden breakdown Facilitates proper sequence in maintenance service Reliability: Availability Quality over Probability time Component Reliability Reliability Product Reliability Dependability Durability  Component Reliability Definition:  It is the probability that a part or a component will not fail in each time or number of trails under ordinary conditions of use.  Measurement  Component reliability (CR) is usually measured by reliability, failure rates (FR) and mean time between failures (MTBF), i.e. 𝐶𝑅 = 1 − 𝐹𝑅 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠 𝐹𝑅 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑡𝑒𝑠𝑡𝑒𝑑 𝐹𝑅𝑛 = 𝑀𝑇𝐵𝐹 = = Product reliability or system reliability  When components or parts are combined into a larger system, such as a machine or a product, the combined reliability of all the components or parts form the basis for product or system reliability  Calculation of product or system reliability  When critical components interact during the operation of the product or system, the reliability of the product or system is determined by computing the product of the reliabilities of all the interacting critical components.  SR = CR1*CR2*…..*CRn  Turn out a reliable product FIVE KEY AREAS DESIGN OF THE PRODUCTION MEASUREMENT MAINTENANCE FIELD OF PRODUCT AND TESTING OPERATION  Conclusion: To ensure effective implementation of activities, it is important that the production facilities need to be maintained in good working condition. Reduces cost, machinery breakdown etc Quality assurance Therefore, maintenance management is an important aspect for any organization 46