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Wire Routing System (WRS) Systems Engineering Management Plan
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Wire Routing System (WRS)
Systems Engineering
Management Plan
(SEMP)
5 October 2015
Wire Routing System (WRS) Systems Engineering Management Plan
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Document Control
Created
By:
Name: Title: Date:
Brian Davidson Project Manager 23-Sep-15
Theresa D’Amore Deputy Project Manager 23-Sep-15
Chad Vance Systems Engineer, Integration 23-Sep-15
Andrew Schuettpelz Systems Engineer, SME 23-Sep-15
Kyle Lopez Systems Engineer, IT 23-Sep-15
Sachin Mehta Systems Engineer, V&V 23-Sep-15
Reviewed By:
Name: Date:
2-Oct-15
Wire Routing System (WRS) Systems Engineering Management Plan
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Table of Contents
1	
   SEMP / Project Overview.................................................................................................. 7	
  
1.1	
   Need Statement........................................................................................................... 7	
  
1.2	
   Project Structure ......................................................................................................... 9	
  
2	
   Business Case .................................................................................................................... 9	
  
3	
   Requirements Development Process ............................................................................... 10	
  
3.1	
   Customer Requirements............................................................................................ 10	
  
3.2	
   Derived Requirements .............................................................................................. 12	
  
3.3	
   Requirements Analysis and Prioritization ................................................................ 13	
  
4	
   System Architectures....................................................................................................... 14	
  
4.1	
   Functional Analysis .................................................................................................. 14	
  
4.1.1	
   Functional Architecture Description.................................................................. 14	
  
4.2	
   Concept Exploration................................................................................................. 14	
  
4.3	
   Architecture & Design Specifications ...................................................................... 15	
  
4.3.1	
   Technology Market Survey ............................................................................... 15	
  
4.3.2	
   Physical Architecture......................................................................................... 17	
  
4.3.3	
   Architecture Documentation.............................................................................. 18	
  
4.3.4	
   Architecture Quality Attributes ......................................................................... 18	
  
5	
   System Verification and Validation................................................................................. 18	
  
6	
   Design Model................................................................................................................... 20	
  
7	
   Project Summary ............................................................................................................. 22	
  
7.1	
   Work Breakdown Structure...................................................................................... 22	
  
Project Management WBS ................................................................................................ 22	
  
Systems Engineering WBS................................................................................................ 23	
  
Interface Systems WBS..................................................................................................... 23	
  
Control System WBS......................................................................................................... 23	
  
Mechanical System WBS .................................................................................................. 23	
  
Management Reserve WBS............................................................................................... 23	
  
Assembly and Test WBS................................................................................................... 23	
  
Sustainment WBS.............................................................................................................. 23	
  
7.2	
   Project Plan............................................................................................................... 24	
  
7.3	
   Risk Management..................................................................................................... 24	
  
8	
   Lifecycle Management Plan ............................................................................................ 24	
  
8.1	
   Deployment Plan ...................................................................................................... 24	
  
8.2	
   Support Plan.............................................................................................................. 24	
  
8.3	
   Cost Estimates .......................................................................................................... 24	
  
9	
   Appendices ...................................................................................................................... 25	
  
9.1	
   Appendix I Requirements......................................................................................... 25	
  
9.2	
   Appendix II Requirements Analysis......................................................................... 29	
  
9.3	
   Appendix III Architecture......................................................................................... 31	
  
9.4	
   Appendix IV V & V ................................................................................................. 33	
  
9.5	
   Appendix V Market Research .................................................................................. 38	
  
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List of Tables
Table 4-1 First and second place technology options................................................................... 16	
  
Table 4-2 Technology Compatibility Matrix................................................................................ 17	
  
Table 4-3 Physical Architecture Alternatives............................................................................... 18	
  
Table 9-1 Use and misuse case scenarios based upon the use case diagram................................ 25	
  
Table 9-2 Complete list of WRS customer requirements............................................................. 27	
  
Table 9-3 Complete list of WRS derived requirements................................................................ 27	
  
Table 9-4 WRS evaluation criteria matrix.................................................................................... 29	
  
Table 9-5 WRS requirements prioritization matrix ...................................................................... 30	
  
Table 9-6 Four (4) Phase Test Plan............................................................................................... 33	
  
Table 9-7 Review Gate Table ....................................................................................................... 34	
  
Table 9-8 Validation Matrix ......................................................................................................... 35	
  
Table 9-9 Compliance Matrix....................................................................................................... 36	
  
Table 9-10 WRS Traceability....................................................................................................... 37	
  
Table 9-11 Technology Impact Matrices...................................................................................... 38	
  
Table 9-12 Technology Options ................................................................................................... 39	
  
Wire Routing System (WRS) Systems Engineering Management Plan
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List of Figures
Figure 1.1- Wire Harness _______________________________________________________ 7	
  
Figure 1.2 - Form Board ________________________________________________________ 7	
  
Figure 1.3 Wire Harness Fabrication Process________________________________________ 8	
  
Figure 1.4 Wire Routing System Model____________________________________________ 9	
  
Figure 3.1	
  WRS	
  use	
  case	
  diagram_______________________________________________ 11	
  
Figure 3.2 Use case for route wire _______________________________________________ 11	
  
Figure 3.3	
  Derived	
  Requirements	
  traceability	
  back	
  to	
  Customer	
  Require______________ 13	
  
Figure 4.1 Ranked Architecture Alternatives _______________________________________ 15	
  
Figure 6.1 Hybrid Communication-Sequence Diagram _______________________________ 21	
  
Figure 6.2 WRS boundary diagram ______________________________________________ 22	
  
Figure 9.1 Affinity diagram of customer requirements _______________________________ 27	
  
Figure 9.2 Functional Tree Diagram______________________________________________ 29	
  
Figure 9.3 Interrelationship Digraph______________________________________________ 31	
  
Figure 9.4 Hatley–Pirbhai modeling _____________________________________________ 32	
  
Figure 9.5 Work Breakdown Structure____________________________________________ 40	
  
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List of Acronyms
AND Activity Network Diagram
COTS Commercial Off-the-Shelf
CR Customer Requirements
ConOps Concept of Operations
DRCM Design Requirements Compliance Matrix
EC Engineering Characteristics
EPA Environmental Protection Agency
FFBD Functional Flow Block Diagram
ICD Interface Control Document
ID Interrelationship Digraph
IEEE Institute of Electrical and Electronics Engineers
INCOSE International Council On Systems Engineering
IPD Integrated Product Team
MMA Morphological Matrix of Alternatives
MOE Measures of Effectiveness
MOP Measures of Performance
MOS Measures of Suitability
NESHAP National Emission Standards for Hazardous Air Pollutants
NFPA National Fire Protection Agency
OSHA Occupational Safety and Health Administration
PM Prioritization Matrix
QFD Quality Function Deployment
SEI Software Engineering Institute
SEMP Systems Engineering Management Plan
SEP Systems Engineering Process
SE Systems Engineering
SME Subject-Matter Expert
TCM Technology Compatibility Matrix
TIM Technology Impact Matrix
V&V Verification and Validation
WBS Work Breakdown Structure
WRS Wire Routing System
Wire Routing System (WRS) Systems Engineering Management Plan
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1 SEMP	
  /	
  Project	
  Overview	
  
1.1 Need	
  Statement	
  	
  
The goal of this project is to provide a proof of concept technology demonstration of a
system for the accurate and repeatable routing of wire in 3D space, during wire harness
manufacturing. Current methods of wire routing rely on antiquated techniques that require
manufacturers to depend heavily on their fabricator’s attention to detail and personal motivation
to produce high-quality products. Manual wire routing is prone to defects, inconsistencies, and
unpredictable spans from initiation to completion. These elements add fabrication cost by
increasing difficulty when planning work, forecasting material usage, and predicting time to
completion. It is approximated that first pass quality defects increase harness costs by 6-12%A.
The cost of poor initial quality is then magnified when lost time is factored into the price of wire
harness fabrication. Therefore, harness manufacturers require a repeatable, accurate, and
affordable system for routing wire during wire harnesses fabrication.
Figure 1.1- Wire Harness
Image found at www.quickwireharness.com/
Figure 1.2 - Form Board
Image found at www.supremecable.com/
The Wire Routing System (WRS) will meet these industry needs through the use of
automation, which will reduce touch labor hours and routing error. Precision mechanics further
improve accuracy and repeatability. The use of automation for wire routing is unprecedented; it
will require acute attention to our customers’ priorities throughout the entire systems engineering
lifecycle. Aerospace and automotive harnesses manufacturers are the intended customers for the
WRS. Utilizing the priorities of our customer, this document will ensure the value of
repeatability, accuracy, ease of use, increased reliability, and the use of existing technologies is
emphasized throughout the decision making process.
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Development of an unprecedented system leaves this project
vulnerable to increased levels of risk in the form of unknown-
unknowns and scope creep. In an effort to mitigate this, several key
assumptions were established from the inception of the WRS. The
WRS concept demonstrator will:
• Route a single wire at a time
• Cut wire to designed length
• Keep the final product in designed configuration until user is
ready for product removal
The wire harenss fabrication process was mapped to illustrate the
scope of the WRS and maintain project focus in. See Figure 1.3,
highlighted in green is the element of wire harness fabrication that is
the focus of this effort. Planned future development will incrementaly
expand the capabilities of the WRS and will incorporate other
elements of the fabrication process; this is discussed further in the
verification and validation section of this document.
Figure 1.3 Wire Harness Fabrication Process
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Figure 1.4 Wire Routing System Model
The next steps in the team’s process involved the use of well-defined customer values,
narrow scope, and a disciplined systems engineering approach to develop and evaluate various
technologies in an effort to meet the customer needs. Based on our thorough analysis, we
recommend the WRS be internally funded for further development. The WRS will quickly
provide higher quality harnesses, with superior consistency than the current solutions. The WRS
is a competitive advantage that positions us to earn new lines of business.
1.2 Project	
  Structure	
  
To be developed during ASE 6004
2 Business	
  Case	
  
To be developed during ASE 6004
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3 Requirements	
  Development	
  Process	
  
Customer requirements were developed to define what the system should provide as well as
define any system constraints. Well-written and thorough requirements have been critical to the
success of the WRS because they ensure key customer needs are fulfilled.
In	
  order	
  to	
  begin	
  the	
  process	
  of	
  defining	
  requirements	
  for	
  the	
  WRS,	
  the	
  customers	
  and	
  
multiple	
  stakeholders	
  were	
  consulted	
  to	
  help	
  identify	
  the	
  essential	
  needs	
  that	
  the	
  system	
  
should	
  fulfill.	
  	
  The	
  customers	
  and	
  stakeholders	
  solicited	
  during	
  this	
  process	
  are	
  listed	
  
below:	
  
	
  
The target customers of the WRS will be wire harness manufacturers in both the automotive
and aviation industries. All other groups listed above are stakeholders of the WRS and are
important because they impose requirements on the system. For example, wire manufactures
produce wire of a certain size and type which means the WRS must be compatible with wire
provided.
3.1 Customer	
  Requirements	
  
Generating requirements for an innovative product is a difficult process because there is not
a clear understanding of the end product when the process begins. For this reason, the integrated
development team (IDT) utilized brainstorming sessions and created use cases to help generate
requirements. These two strategies will be discussed in further detail within this section.
Brainstorming sessions with the customers and stakeholder were a great way to identify
requirements for the system. The result was a large number of requirements, which served to
address the wide variety of needs and constraints on the WRS. Brainstorming also resulted in a
rough understanding of the system functionality. Based upon the results, the system should
receive inputs from a variety of operators, perform its intended function and then output a wire,
which is routed into a specific design.
The rough understanding of the WRS functionality gained from the brainstorming sessions
allowed the IDT to then create a use case diagram. This use case diagram can be seen in Figure
3.1 below.
§ Wire	
  Harness	
  Manufacturers	
   § Wire	
  Manufacturers	
  
§ Sustainment	
  Personnel	
   § Wire	
  Routing	
  Technicians	
  
§ Harness	
  Designers	
   § Quality	
  Control	
  
§ Wire	
  Harness	
  End	
  Users	
   § Regulatory	
  Agencies	
  
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Figure 3.1	
  WRS	
  use	
  case	
  diagram
The use case diagram of the WRS helped to identify requirements that were not generated
during the brainstorming sessions. Note that WRS operators have been broken up into operators
of individual actions. This was done to provide more insight into the individual interactions
between the actors and the WRS. Identifying interactions and developing use case scenarios for
them helped flush out additional requirements. Figure 3.2 provides an example of one use case
scenario as well as the customer requirements that were derived from it.
Figure 3.2 Use case for route wire
The use case scenario presented a pre-condition where the WRS has a harness design loaded
and the correct wire available to it. The basic flow section illustrates the actions taken by the
operator and the WRS response to those actions. As an example of how use cases helped in
generating customer requirements, Step 3 states that the WRS terminates (cuts) the wire at the
Use	
  Case	
  Name 2.2	
  Navigate	
  Wire	
  in	
  3D	
  Space
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  Routes	
  wire	
  based	
  upon	
  the	
  3	
  dimensional	
  
design	
  provided	
  to	
  it
Actor System	
  Command	
  Operator
Pre-­‐conditions WRS	
  has	
  successfully	
  received	
  the	
  desired	
  wire	
  routing	
  design	
  and	
  wire	
  
and	
  is	
  prepared	
  to	
  execute	
  wire	
  route	
  design
Post-­‐conditions Wire	
  is	
  routed	
  along	
  the	
  desired	
  3	
  dimensional	
  route	
  and	
  constrained	
  in	
  
place
Misuse	
  Scenarios a.	
  	
  Wire	
  feed	
  runs	
  out	
  of	
  wire
b.	
  	
  Wire	
  is	
  not	
  constrained	
  properly	
  and	
  falls	
  out	
  of	
  configuration
Basic	
  Flow 1.	
  	
  Operator	
  commands	
  the	
  WRS	
  to	
  begin	
  routing	
  operation
2a.	
  	
  WRS	
  converts	
  design	
  path	
  format	
  into	
  mechanical	
  motion
2b.	
  	
  WRS	
  feeds/lays/guides/prints	
  wire	
  along	
  the	
  design	
  path	
  
2c.	
  	
  WRS	
  constrains	
  the	
  wire	
  along	
  the	
  design	
  path	
  configuration	
  as	
  
	
  	
  	
  	
  	
  	
  the	
  wire	
  is	
  put	
  in	
  place
3.	
  	
  WRS	
  system	
  terminates	
  wire	
  at	
  the	
  end	
  of	
  the	
  wire	
  route	
  path
4.	
  	
  WRS	
  communicates	
  to	
  Operator	
  that	
  the	
  wire	
  route	
  is	
  complete
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end of the wire route path. This particular step indicated the need for a requirement on the WRS
to limit the wire that exists outside of the routed envelope.
In addition to the use cases in Figure 3.2, four (4) more use cases were developed for the
following WRS-Operator interactions:
• Receive	
  Wire	
  Path	
  Design	
  
• Receive	
  Wire	
  
• Accommodate	
  Removal	
  of	
  Wire	
  
• Receive	
  Input	
  
The use cases can be seen in Table 9-1 in Appendix I along with their respective misuse
cases.
A large number of customer requirements resulted from the use case scenarios and
brainstorming sessions. To help organize and consolidate the requirements, the team utilized
two key analysis tools; an affinity diagram and a tree diagram. The affinity diagram served to
group the large amount of scattered requirements. This grouping is shown in Appendix I, Figure
9.1. By doing this, the team was able to identify requirements that were similar and could be
consolidated. The full list of customer requirements can be seen in Appendix I, Table 9-2. Once
the customer requirements were grouped and consolidated, they were organized by function and
structured into a tree diagram. The WRS tree diagram can be seen in Appendix I, Figure 9.2.
This began to paint a picture of how the system should be structured. It also identified gaps that
the customer requirements didn’t address. The next step was to derive requirements to fill the
gaps.
3.2 Derived	
  Requirements	
  
Derived requirements are not explicitly stated in the set of customer requirements, yet are
necessary to satisfy one or more of them. The tree diagram made it clear which customer
requirements needed to be elaborated on. Figure 3.3 below shows several examples of
requirements that were derived from the list of customer requirements
	
  
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Figure 3.3	
  Derived	
  Requirements	
  traceability	
  back	
  to	
  Customer	
  Require	
  
The full list of derived requirements and their traceability back to the customer requirements
can be seen in Appendix I, Table 9-3.
	
  
3.3 Requirements	
  Analysis	
  and	
  Prioritization	
  
Once all of the customer and derived requirements were established and traceable, the team
segregated the high level customer requirements and prioritized them based on customer
importance. This was accomplished using an evaluation criteria matrix and a requirements
prioritization matrix. First, the customer needs were scored against one another in the evaluation
criteria matrix to determine the correct weighting associated with each one with respect to the
others. This table can be seen in Appendix II, Table 9-4. Next, the high level customer
requirements were ranked against one another based upon how vital they were to each weighted
customer need. This process helped to identify the customers’ highest priority requirements and
their respective derived requirements. The requirements priority matrix can also be seen in
Appendix II, Table 9-5.
The requirements development process helped to achieve a solid understanding of all the
requirements and their priorities, which set the stage for the functional architecture development.
	
  
	
  
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4 System	
  Architectures	
  
4.1 Functional	
  Analysis	
  	
  
4.1.1 Functional	
  Architecture	
  Description	
  	
  
Based on the customer and derived requirements we developed a functional decomposition
tree depicted in Figure 9.2 in Appendix I . The major system functions were identified, broken
down and in some cases eliminated where necessary to remain within the project scope. This not
only helped to identify testable conditions but also to derive further requirements. As the team
broke down each function we began to establish the limits and boundaries of the WRS.
Traceability of each function back to the original WRS customer requirements can be seen in Appendix
IV Table 9-10.
The tier 1 functions of our decomposition were Utility, Operation and Sustainment. Of
these, the Operation decomposition led to most of the architectural features, while the Utility and
Sustainment sub-functions greatly assisted in understanding the boundaries.
The WRS functional architecture diagram is the baseline description of the WRS
functionality and can be seen in the Hatley–Pirbhai model, Appendix III, Figure 9.4. From this
functional decomposition we considered the sequence of the systems primary functions and how
they relate to one another on many levels.
The team decided to focus on the five key functions that drive the unique capability of this
system.
• 2.1.1 Receive Wire Path Design
• 2.1.2 Deploy Wire
• 2.2 Route Wire
• 2.3.2 Accommodate Removal of Wire
• 2.1 Receive Input
This led to the development of a Hybrid Communication-Sequence model to address the
flow of data and material throughout our system, see Section 6, Figure 6.1. The team also created
a system boundary model to illustrate critical internal subsystem boundaries and how the WRS
relates to external systems.
4.2 Concept	
  Exploration	
  	
  
Basic requirements of the system were established using industry need, as identified by
experts. Varying levels of complexity were brainstormed. An interrelationship digraph was
used to determine the sensitivity of early system requirements, see appendix III, Figure 9.3. User
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interaction, routing wire to design specification, and maintainable were shown to be the most
sensitive. It indicated that the preferred alternatives are focused on satisfying the most sensitive
requirements. This focus will ensure robustness of the WRS design and reinforces the rational of
the design architecture choices made by the team.
	
  	
  	
  	
  
The IDT used pair-wise comparisons to prioritize the customer requirements and used these
prioritized requirements to evaluate technology solutions identified during the technology market
survey (TMS) based on their ability to fulfill the prioritized customer values from the technology
impact matrix (TIM). A technology compatibility matrix (TCM) was then utilized to eliminate
configurations that would not allow for full system functionality. The remaining options were
organized into four (4) physical architecture alternatives. Each alternative was ranked against
one another with respect to the five (5) prioritized customer values using the analytical hierarchal
process. The analysis revealed that two (2) of the alternatives would be best suited to fulfill the
customer need. Figure 4.1, Ranked Architecture Alternatives With only a 1.79% discrepancy
between these alternatives, the IDT decided that further evaluation is needed to distinguish the
two (2) options and will be performed during a later iteration of the systems engineering process.
Figure 4.1 Ranked Architecture Alternatives
4.3 Architecture	
  &	
  Design	
  Specifications	
  
4.3.1 Technology	
  Market	
  Survey	
  	
  
The WRS architectural design began with exhaustive technological research on five (5) key
functionalities, outlined above in the functional architecture description, Section 4.1.1. The
technology exploration illustrates information from a breadth of resources. These requirements
took precedence in the analysis because they represent the underpinnings of development and
will be integral in eventual system performance. The five (5) measures of effectiveness (MOE),
which were refined by the integrated design team (IDT) served as the set of evaluation criterion
in order to determine MOE relative importance amongst one another. The following is a
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summary of the evaluation criteria matrix Appendix II, Table 9-4 and depicts the final % relative
importance of each respective MOE.
-­‐ Accuracy/Repeatability = 31%
-­‐ Simplified User Operation = 10%
-­‐ Increased Reliability = 20%
-­‐ Lower Operating Cost = 28%
-­‐ Use of Existing Technology = 11%
Implementation of a TIM for each of the five (5) key functionalities provided a quantified
analysis on technology options and their ability to meet each MOE. The next table displays the
1st
and 2nd
place technology options that arose from each TIM study.
Table 4-1 First and second place technology options
Technology	
  Option	
  	
  
WRS	
  Function	
   1st	
  Place	
  	
   2nd	
  Place	
  
Ref	
  2.1	
  –	
  Receive	
  
Input	
  	
  	
  
Form	
  Based	
  (29%)	
  	
   WIMP/GUI	
  (27%)	
  
Ref	
  2.1.1	
  –	
  Receive	
  
Wire	
  Path	
  Design	
  	
  
Universal	
  Serial	
  Bus	
  (38%)	
   Wired	
  Network	
  (36%)	
  
Ref	
  2.1.2	
  –	
  Receive	
  
Wire	
  	
  
Gear	
  Wheel	
  Straightener	
  
(31%)	
  
Conveyorless	
  (28%)	
  
Ref	
  2.2	
  –	
  Route	
  
Wire	
  	
  
Linear	
  Ball	
  Slide	
  (46%)	
   Belt	
  Driven	
  (40%)	
  
Ref	
  2.3.2	
  –	
  
Accommodate	
  Removal	
  
of	
  Wire	
  	
  
Mechatronics	
  (71%)	
  
Operator	
  Based	
  Modular	
  
Equipment	
  (29%)	
  
This data analysis shows a major distinction (highlighted in red) between the ‘mechatronics’
and ‘operator based modular equipment’ characteristics—with ‘mechatronics’ yielding a 42%
more impact to meet the WRS functional needs. This variation occurred for two (2) reasons:
1) The 9:3 ratio ‘mechatronics’ had against ‘operator based modular equipment’ for the
MOE of accuracy/repeatability.
2) The 9:1 ratio ‘mechatronics’ had against ‘operator based modular equipment’ for the
MOE of lower operating cost.
On the other hand, the four (4) other WRS functions that were analyzed with a TIM showed
a relatively low % discrepancy among technology options—all between 2-6%. Further iterations
of trade studies will be performed in the future to compare technology options with more
specificity. For example, there are various mechatronic and robotic technology designs available
on the market that could possibly fit the WRS needs—so discriminating against them with
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another TIM study will continue through Phase 1 of the test plan, Section 5, until PDR. An exact
replica of each TIM study can be referenced in Appendix V, Table 9-11.
Additional market survey analyses on three (3) low-impact WRS functions can be examined
in Appendix V, Table 9-12. It should be noted, however, that these are not TIM studies, but do
help break down the following WRS functions:
-­‐ Ref. 1.1 Power Supply
-­‐ Ref. 1.2.2 Remove Exhaust/Particulate
-­‐ Ref. 2.1.1.1 Translate Design to Route
4.3.2 Physical	
  Architecture	
  
Compatibility amongst technologies was the next analysis performed to down-scale physical
architecture options using a TCM, Table 4-2 below. This technique discriminated amongst WRS
technology options; those that would not be able to perform, or integrate, with one another.
Table 4-2 Technology Compatibility Matrix
1	
  =	
  Incompattable
Form	
  Based
Capacitive	
  Touch	
  HMI
Command	
  Line
WIMP/GUI
Wired	
  Network
USB	
  2.0/3.0
Cloud	
  Based
Gear	
  Wheel	
  
Straightener
Bearing	
  Wheel	
  
Straightener
Conveyorless
Crank	
  Wheel
Belt	
  Driven
Linear	
  Ball	
  Slide
Manual	
  Peg	
  Board
Operator	
  Based	
  
Modular	
  Equipment
Mechatronics
Ref.	
  2.1.2	
  Receive	
  Wire
Ref.	
  2.3.2	
  
Accommodate	
  
Removal	
  of	
  
Wire
Ref.2.2	
  Route	
  
Wire
Ref.	
  2.1	
  Receive	
  Input
Ref.	
  2.1.1	
  Receive	
  
Wire	
  Path	
  Design
Form	
  Based 0 1 1 1 1 1
Capacitive	
  Touch	
  
HMI
0 1 1 1 1
Command	
  Line 0 1 1 1
WIMP/GUI 0 1 1
Wired	
  Network
0 1 1 1 1
USB	
  2.0/3.0
0 1 1 1
Cloud	
  Based
0 1 1
Gear	
  Wheel	
  
Straightener
0 1 1 1 1 1
Bearing	
  wheel	
  
straightener
0 1 1 1 1
Conveyorless
0 1 1
Crank	
  Wheel 0 1 1 1
Belt	
  Driven
0 1 1 1
Linear	
  Ball	
  Slide 0 1 1
Manual	
  Peg	
  Board 0 1
Operator	
  Based	
  
Modular	
  
0 1
Mechatronics 0
Ref.2.2	
  Route	
  Wire
Ref.	
  2.3.2	
  
Accommodate	
  
Removal	
  of	
  Wire
Ref.	
  2.1	
  Receive	
  
Input
Ref.	
  2.1.1	
  Receive	
  
Wire	
  Path	
  Design
Ref.	
  2.1.2	
  Receive	
  
Wire
Wire Routing System (WRS) Systems Engineering Management Plan
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Results of this analysis poised the IDT assigned to the WRS to arrive at four (4) varying
physical design architectures shown below in Table 4-3.
Table 4-3 Physical Architecture Alternatives
These four (4) architecture alternatives include:
-­‐ High TRL Interface
-­‐ Advanced Interface
-­‐ Easy to Use
-­‐ Bare Bones Basic
Two (2) of the architecture alternatives only differ in the WRS function Ref. 2.1 Receive
Input: the ‘High TRL Interface’ and ‘Advanced Interface’ alternatives, while the others have a
greater deal of variation among technology options.
These architecture alternatives will include a list of interface control documents, which will
be adequately defined and documented for PDR in the future.
4.3.3 Architecture	
  Documentation	
  
To be developed during ASE 6004
4.3.4 Architecture	
  Quality	
  Attributes	
  
To be developed during ASE 6004
5 System	
  Verification	
  and	
  Validation	
  	
  
We have been and will be preforming review and test sequences throughout our system’s
development. The team intends to use a mix of Informal, Static and Dynamic verification and
validation methods. A compliance matrix is included in Appendix IV, Table 9-9 to ensure that
requirements set by regulatory bodies are met.
The team has established a series of preliminary design review (PDR) entrance and exit
criteria. Similar reviews will be performed to ensure that the engineering team does not lose sight
of the customer need. Critical stages of development will include multiple reviews. Each of
WRS	
  Function High	
  TRL	
  Interface Easy	
  to	
  Use Bare	
  Bones	
  Basic Advanced	
  Interface
Ref.	
  2.1	
  Receive	
  Input Form	
  Based WIMP/GUI Form	
  Based WIMP/GUI
Ref.	
  2.1.1	
  Receive	
  
Wire	
  Path	
  Design Wired	
  Network USB	
  2.0/3.0 USB	
  2.0/3.0 Wired	
  Network
Ref.	
  2.1.2	
  Receive	
  
Wire Gear	
  Wheel	
  Straightener Bearing	
  Wheel	
  Straightener Conveyorless
Gear	
  Wheel	
  
Straightener
Ref.	
  2.2	
  Route	
  Wire Linear	
  Ball	
  Slide	
   Belt	
  Driven Belt	
  Driven Linear	
  Ball	
  Slide
Ref.	
  2.3.2	
  
Accommodate	
  
Removal	
  of	
  Wire
Mechatronics Mechatronics
Operator	
  Based	
  
Modular	
  Equipment
Mechatronics
Physical	
  Architecture	
  Alternatives
Wire Routing System (WRS) Systems Engineering Management Plan
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~    1 9    ~
these reviews will compare the stated goals of a stage and the results; all criteria must be
satisfied before moving on to the next stage.
A similar review will be performed at the onset of each new stage to properly define and
communicate the goals to the team. These verification activities will take place throughout the
research and development of the WRS, however, during procurement and integration a much
more formal process will be utilized. For these critical stages a four phase validation plan has
been developed and can be found in Appendix IV Tables 9-6 and 9-7. The 4 phases are as
follows:
Phase	
  1	
   Phase	
  2	
   Phase	
  3	
   Phase	
  4	
  
Individual	
  Component	
  
Testing/	
  Middleware	
  AoA	
  
Subsystem	
  
Integrations	
  
System	
  Level	
  
Integrations	
  
Prototype	
  Testing	
  incl.	
  
Operation	
  and	
  Quality	
  
Phase 1 will address the entry and exit to the component procurement stage of the project.
An evaluation of the various component options that resulted from our technology market study
will be used to develop further AoAs of the identified technology suites. Each suite will be
defined by the communication protocols and signals utilized; a technology impact matrix (TIM)
will ensure that no incompatibilities are built in to the WRS.
Phase 2 will mirror phase 1, incorporating mechanical and structural considerations. The
results of this stage will derive further requirements for the selection of the WRS operating
system.
Phase 3 will run through a similar process as the previous two phases, this time for the
assembled subsystems. Testing of the software operating system that best fits the decisions made
in Phases 1 & 2 will occur as well.
While each phase will be broken up into various subsections for continuity, those in Phase 4
are the most critical and must be considered very early in development for the project’s success.
Once cleared to proceed to Phase 4 the team will begin integrating those subsystems that resulted
from Phases 2 & 3. The first stage (Appendix IV, Table 9-6, Phase 4.1) of Phase 4 will review
the mechanical and structural interfaces. Upon acceptance of Review Gate 4.2(Appendix IV,
Table 9-7) operational testing (Appendix IV, Table 9-6, Phase 4.2) will begin to confirm that the
software and control systems react as expected during both normal operation as well as fault and
failure scenarios.
Once operational testing has been successfully completed, quality testing will begin. This
stage (Appendix IV, Table 9-6, Phase 4.3) will address the ability of the WRS to produce a
consistent product within the required specifications and confirm the systems durability. Phase 4
testing will be deemed successful once a technology demonstration has been performed and the
customer is satisfied with the results. However, in the event that the system does not perform as
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 0    ~
expected the team will continue to the Rework (Appendix IV, Table 9-6, Phase 4.4) and Retest
(Appendix IV, Table 9-6, Phase 4.5) stages.
It is very important to note that review gates scheduled during this plan will elicit and allow
the team to act upon stakeholder feedback relevant to the progress and direction of the WRS.
A fifth phase will be implemented upon customer acceptance of the proof of concept system.
Phase 5 will include production validation, hardware improvements, additions and software
upgrades while verifying that the customer needs continue to drive development.
6 Design	
  Model	
  	
  
The WRS has a complex set of communication requirements between components, which
requires a rigid set of boundary definitions. The following hybrid communication-sequence
diagram demonstrates how data traverses the WRS from user execution through the WRS and to
the delivery system.
The WRS boundary diagram shows communications between hardware-software-hardware.
Each item that has a shared border in the graph is illustrating that there are communications
between them. Items within a red box are out of scope for our project, but still have
communications between them. This communication must be further developed for each
incremental upgrade in system capability.
Wire Routing System (WRS) Systems Engineering Management Plan
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~    2 1    ~
Figure 6.1 Hybrid Communication-Sequence Diagram
Feeds wire on
demand
Attributes
Wire De-reeler
Routes physical
wire in 3D space
One routes a
single wire at a
time
Motors/PLCs
Middleware
Transfers data to
low level
middleware
Hard/software
WRS UX
Feeds wire on
demand
Holder of final
product
Wire Delivery
Request wire
from external
system
Send sequence
to low level
hardware
Move final
product to
delivery state
Inform user that
product is final
Wire Routing System (WRS) Systems Engineering Management Plan
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~    2 2    ~
Figure 6.2 WRS boundary diagram
7 Project	
  Summary	
  
To be developed during ASE 6004
7.1 Work	
  Breakdown	
  Structure	
  
The WBS for the entire system development program is shown in Appendix V, Figure 9.5.
Each separate root (W<single digit #>) is a tier 1 level in the breakdown. Delineating from those
are the next work breakdown tiers and they reflect other major elements of the WRS program in
its entirety, from assembly and test to sustainment.
	
   Project	
  Management	
  WBS	
  
The WBS W1 refers to all elements related to the WRS program development, including
vendor oversight, procurement management, and facility related issues.
User/Software
UX
Version 1 «precondition» pre
«postcondition» post
Wire De-reeler
«precondition»
Wire present
«postcondition»
WRS requesting wire,
or FIN signal
Delivery system
«precondition»
Wire harness present
«postcondition»
Remove final product
3D CAD codec
Version 1
Hardware
Version 1
WRS 3D
encoding
Version 1
Middleware
Version 1
High2Low translator
Version 1
Sequencing
Version 1
PLC
Version 1
Adadapters/
Connectors
Version 1
Structure
Version 1
Out of bounds Software Hardware Enclosure
Wire Routing System (WRS) Systems Engineering Management Plan
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~    2 3    ~
	
   Systems	
  Engineering	
  WBS	
  
The WBS W2 involves the development of technical expertise, SEMP and the ConOps.
Understanding and updating of related technical documentation falls upon these R&D and
product development personnel.
	
   Interface	
  Systems	
  WBS	
  
The WBS W3 falls under the purview of the SME in relation to interface systems
technology. PDR on this issue will come through his or her oversight, and will be founded upon
appropriate research and documentation.
	
   Control	
  System	
  WBS	
  
The WBS W4 provides a breakdown of work associated with WRS control system
development. This includes process control, automation, and regulation of electro-mechanical
systems.
	
   Mechanical	
  System	
  WBS	
  	
  
The WBS W5 for the Mechanical System is the most extensive aspect of the WRS. This
work breakdown involves hardware design and fabrication, component integration, along with a
large amount of V&V activities.
	
   Management	
  Reserve	
  WBS	
  
In order to better accommodate best practices, an allotted amount of reserve funds will be
distributed amongst three (3) sectors of WRS development: quality risk, cost risk, & schedule
risk. Early acknowledgement that there is a certain amount of risk involved in full scale
development provide a greater probability of success.
	
   Assembly	
  and	
  Test	
  WBS	
  
The WBS W7 for Assembly and Test provides process quality management in regards to
complete fabrication of validated devices. This will be supervised by the all W2.2 personnel
including: electrical lead, mechanical lead, team lead, software lead, and drafter.
	
   Sustainment	
  WBS	
  
The WBS W8 heavily details the development of manuals and training. Maintenance
schedules for the WRS will be discussed and developed, along with repair procedures for system
components. It is the responsibility of the PM and the SE to lead this process to completion.
Wire Routing System (WRS) Systems Engineering Management Plan
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~    2 4    ~
7.2 Project	
  Plan	
  
To be developed during ASE 6004
7.3 Risk	
  Management	
  
To be developed during ASE 6004
8 Lifecycle	
  Management	
  Plan	
  
To be developed during ASE 6004
8.1 Deployment	
  Plan	
  
To be developed during ASE 6004
8.2 Support	
  Plan	
  
To be developed during ASE 6004
8.3 Cost	
  Estimates	
  	
  
The cost estimates were derived by first identifying the top elements from our work
breakdown schedule. This included:
• Project Management
• Systems Engineering
• Interface Systems
• Control System
• Mechanical Systems
• Assembly and Test
• Management Reserve
• Sustainment
Second, using our determined deliverable life cycle methodology, we identified our tier one
cost elements from the WBS, and the subordinate elements in relation to our project life
cycle. The team labeled risks for each cost element, and the type of distribution patterned
matched each element’s risk factors. Some factors that influenced risks to the project were,
supply chain management, integration factors, scope, resource conflicts, changing customer
requirements and political influences.
Project Management: The project manager will be most crucial at the beginning of the
project, but will still be integral throughout the entire life cycle. We used a lognormal
distribution because the risks at the beginning are very high, but die slowly as the project reaches
the end of life.
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 5    ~
Systems Engineer: Like the project manager the systems engineer will be critical to the
entire project life cycle, but will have slightly less risk in the beginning, and the highest amount
of risk will be centered around the integration, validation and verification phase because of this
we chose a Gaussian distribution.
Interface Systems: The interface system has its highest amount of risk around beginning to
middle of the whole project life. The risk for this element comes from unit testing each
software/hardware component, and integration with the rest of the system. We believe that this
risk pattern is best modeled with a Gaussian distribution.
Control Systems: The control system development is the cost element that pertains to the
translating of 3D cad file to a time-series plan for each mechatronic component to route a wire in
3D space. The risk for this cost element is Gaussian because it is needed for
Mechanical Systems: The risks for the mechanical systems has the greatest amount of the
risk due to the amount and variety of mechatronic components as well as the supply chain
logistics to obtain the parts. The amount of risk best fit a triangular (Mean (a+b+c)/3; Variance
(a^2+b^2+c^2 –ab-ac-bc)/18) distribution curve because this cost element changes significantly
through each phase due to integration.
Assembly and Test: The assembly and testing of all the component is a vital cost element
for this project. Because we are using items with a higher technology readiness we won’t have as
a high of a risk at any one phase of the project, but we will have a lognormal (Mean (e^µ+
σ^2)/2; Variance ((e^ σ^2) -1)(e^2*µ+ σ^2)) distribution curve that will slowly go to zero as the
project finishes its full life cycle.
Management Reserve: The management reserve fund is a fixed cost, and will provide the
project with a set of monies for project issues that are unforeseen, or need extra resources to keep
the project on time.
Sustainment: Sustainment will cover development of maintenance and repair guides, as
well as personnel to do the actual repairs/maintenance. This element will be later in the whole
project life cycle, and should be have a lesser amount of risk because it is at the end of
development. This is why we believe that the risk pattern for this is a normal distribution curve.
	
  
9 Appendices	
  
9.1 Appendix	
  I	
  Requirements	
  
Table 9-1 Use and misuse case scenarios based upon the use case diagram
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 6    ~
Use	
  Case	
  Name 2.1.1	
  Receive	
  Wire	
  Path	
  Design Parent	
  Use	
  Case	
  Name 2.1.1	
  Receive	
  Wire	
  Path	
  Design
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  receives	
  a	
  3	
  dimensional	
  wire	
  harness	
  design	
  
from	
  operator
Misuse	
  Case	
  ID 2.1.1a	
  	
  Unrecognized	
  file	
  type	
  loaded
Actor Route	
  Design	
  Operator Misuse	
  Case	
  Description WRS	
  does	
  not	
  recognize	
  the	
  wire	
  harness	
  design	
  file	
  format
Pre-­‐conditions WRS	
  has	
  no	
  wire	
  harness	
  design	
  to	
  execute Actor Operator
Pre-­‐conditions WRS	
  has	
  no	
  wire	
  harness	
  design	
  to	
  execute
Basic	
  Flow 1.	
  	
  Operator	
  activates	
  WRS
2.	
  	
  Operator	
  makes	
  the	
  wire	
  harness	
  design	
  available	
  to	
  WRS
3.	
  	
  Operator	
  utilizes	
  WRS	
  user	
  interface	
  system	
  to	
  select	
  correct	
  wire	
  
	
  	
  	
  	
  	
  	
  harness	
  design
4.	
  	
  WRS	
  does	
  not	
  recognize	
  file	
  type	
  
5.	
  	
  WRS	
  generates	
  error	
  message	
  displayed	
  through	
  user	
  interface
6.	
  	
  WRS	
  prompts	
  Operator	
  to	
  re-­‐attempt	
  file	
  selection
Post-­‐conditions WRS	
  has	
  identified	
  wire	
  harness	
  design	
  and	
  is	
  prepared	
  to	
  execute	
  it Post-­‐conditions WRS	
  has	
  communicated	
  file	
  type	
  error	
  and	
  awaits	
  new	
  file
Misuse	
  Scenarios a.	
  	
  Unrecognized	
  file	
  type	
  loaded
Use	
  Case	
  Name 2.1.2	
  Receive	
  Wire	
   Parent	
  Use	
  Case	
  Name 2.1.2	
  Receive	
  Wire	
  
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  receives	
  wire	
  from	
  the	
  Operator Misuse	
  Case	
  ID 2.1.2.a	
  	
  Incorrect	
  wire	
  loaded
Actor Wire	
  Provider	
  Operator	
  	
   Misuse	
  Case	
  Description Operator	
  provides	
  the	
  wrong	
  size/type	
  wire
Pre-­‐conditions WRS	
  has	
  identified	
  wire	
  type	
  and	
  size	
  needed	
  for	
  wire	
  harness	
  design;	
  
Correct	
  wire	
  type	
  and	
  size	
  are	
  available	
  
Actor Operator	
  	
  
Pre-­‐conditions WRS	
  has	
  identified	
  wire	
  type	
  and	
  size	
  needed	
  from	
  wire	
  harness	
  design;	
  
Correct	
  wire	
  type	
  and	
  size	
  are	
  available	
  
Basic	
  Flow 1.	
  	
  WRS	
  communicates	
  to	
  the	
  operator	
  what	
  wire	
  type	
  is	
  need	
  for	
  the	
  
	
  	
  	
  	
  	
  	
  design
2.	
  	
  WRS	
  provides	
  step	
  by	
  step	
  instructions	
  showing	
  operator	
  how	
  to	
  
	
  	
  	
  	
  	
  	
  load	
  wire
3.	
  	
  Operator	
  follows	
  steps	
  presented	
  and	
  prepares	
  the	
  WRS	
  to	
  
	
  	
  	
  	
  	
  	
  receive	
  the	
  wire
4.	
  	
  Operator	
  makes	
  the	
  incorrect	
  wire	
  available	
  to	
  the	
  WRS	
  system
5.	
  	
  WRS	
  recognizes	
  incorrect	
  wire	
  loaded	
  
Post-­‐conditions WRS	
  has	
  successfully	
  received	
  wire	
  and	
  is	
  prepared	
  to	
  execute	
  desired	
  
wire	
  route	
  design
Post-­‐conditions WRS	
  has	
  communicated	
  wire	
  size/type	
  error	
  and	
  awaits	
  correct	
  wire	
  
Misuse	
  Scenarios a.	
  	
  Incorrect	
  wire	
  loaded
Use	
  Case	
  Name 2.2	
  Navigate	
  Wire	
  in	
  3D	
  Space Parent	
  Use	
  Case	
  Name 2.2	
  Route	
  Wire
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  Routes	
  wire	
  based	
  upon	
  the	
  3	
  dimensional	
  
design	
  provided	
  to	
  it
Misuse	
  Case	
  ID 2.2.a	
  Wire	
  feed	
  runs	
  out	
  of	
  wire
Actor System	
  Command	
  Operator Misuse	
  Case	
  Description Operator	
  did	
  not	
  load	
  enough	
  wire	
  to	
  complete	
  route
Pre-­‐conditions WRS	
  has	
  successfully	
  received	
  the	
  desired	
  wire	
  routing	
  design	
  and	
  wire	
  
and	
  is	
  prepared	
  to	
  execute	
  wire	
  route	
  design
Actor WRS,	
  Operator
Pre-­‐conditions WRS	
  has	
  successfully	
  received	
  the	
  desired	
  wire	
  routing	
  design	
  and	
  wire	
  
and	
  is	
  prepared	
  to	
  execute	
  wire	
  route	
  design
Basic	
  Flow 1.	
  	
  WRS	
  communicates	
  to	
  the	
  operator	
  that	
  the	
  WRS	
  is	
  prepared	
  to	
  
	
  	
  	
  	
  	
  	
  execute	
  wire	
  route	
  design
2.	
  	
  Operator	
  commands	
  the	
  WRS	
  to	
  begin	
  routing	
  operation
3.	
  	
  WRS	
  compares	
  wire	
  route	
  design	
  to	
  quantity	
  of	
  wire	
  available	
  in	
  wire
	
  	
  	
  	
  	
  	
  feed
5.	
  	
  WRS	
  generates	
  error	
  message	
  stating	
  insufficient	
  quantity	
  of	
  wire	
  
Post-­‐conditions Wire	
  is	
  routed	
  along	
  the	
  desired	
  3	
  dimensional	
  route	
  and	
  constrained	
  in	
  
place
Post-­‐conditions WRS	
  has	
  communicated	
  wire	
  quantity	
  error	
  and	
  awaits	
  receipt	
  of	
  more	
  
wire	
  
Misuse	
  Scenarios a.	
  	
  Wire	
  feed	
  runs	
  out	
  of	
  wire
b.	
  	
  Wire	
  is	
  not	
  constrained	
  properly	
  and	
  falls	
  out	
  of	
  configuration
Use	
  Case	
  Name 2.3.2	
  	
  Accommodate	
  Removal	
  of	
  Wire Parent	
  Use	
  Case	
  Name 2.3.2	
  	
  Accommodate	
  Removal	
  of	
  Wire
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  enables	
  the	
  removal	
  of	
  a	
  successfully	
  routed	
  
wire	
  which	
  has	
  been	
  constrained	
  in	
  place
Misuse	
  Case	
  ID 2.3.2.a	
  Improper	
  Wire	
  Handling
Actor WRS,	
  Operator Misuse	
  Case	
  Description 1.	
  	
  Wire	
  is	
  not	
  released	
  properly	
  and	
  falls	
  out	
  of	
  configuration
Pre-­‐conditions WRS	
  has	
  successfully	
  routed	
  and	
  constrained	
  wire	
  but	
  it	
  is	
  still	
  contained	
  
within	
  the	
  system
Actor WRS,	
  Operator
Pre-­‐conditions WRS	
  has	
  successfully	
  routed	
  and	
  constrained	
  wire	
  but	
  it	
  is	
  still	
  contained	
  
within	
  the	
  system
Basic	
  Flow 1.	
  	
  WRS	
  communicates	
  to	
  the	
  operator	
  what	
  wire	
  type/size	
  is	
  need	
  for	
  
	
  	
  	
  	
  	
  the	
  desired	
  design
2.	
  	
  	
  WRS	
  provides	
  step	
  by	
  step	
  instructions	
  showing	
  operator	
  how	
  to	
  
	
  	
  	
  	
  	
  	
  load	
  wire
3.	
  	
  Operator	
  does	
  not	
  correctly	
  follow	
  removal	
  steps	
  and	
  wire	
  falls	
  out	
  of	
  
	
  	
  	
  	
  	
  	
  configuration	
  during	
  removal
4.	
  	
  	
  WRS	
  generates	
  error	
  message	
  stating	
  routed	
  wire	
  is	
  out	
  of	
  
	
  	
  	
  	
  	
  	
  	
  configuration
5a.	
  Operator	
  restores	
  wire	
  to	
  correct	
  configuration	
  and	
  proceeds	
  with	
  
	
  	
  	
  	
  	
  	
  	
  	
  removal
5b.	
  Operator	
  removes	
  wire	
  with	
  incorrect	
  configuration	
  and	
  resorts	
  back	
  
	
  	
  	
  	
  	
  	
  	
  	
  to	
  Function	
  2.2.	
  Route	
  Wire
Post-­‐conditions Wire	
  is	
  removed	
  from	
  WRS	
  in	
  the	
  desired	
  route	
  configuration Post-­‐conditions WRS	
  has	
  communicated	
  wire	
  configuration	
  error	
  and	
  awaits	
  	
  next	
  step	
  
from	
  Operator
Misuse	
  Scenarios a.	
  	
  Improper	
  Wire	
  Handling
Basic	
  Flow 1.	
  	
  Operator	
  activates	
  WRS
2.	
  	
  Operator	
  makes	
  the	
  wire	
  harness	
  design	
  available	
  to	
  WRS
3.	
  	
  Operator	
  utilizes	
  WRS	
  user	
  interface	
  system	
  to	
  select	
  correct	
  wire	
  
	
  	
  	
  	
  	
  	
  harness	
  design
4.	
  	
  WRS	
  System	
  recognizes	
  file	
  format	
  of	
  wire	
  harness	
  design
5.	
  	
  WRS	
  indicates	
  that	
  receipt	
  of	
  wire	
  harness	
  design	
  was	
  successful
Basic	
  Flow 1.	
  	
  Operator	
  commands	
  the	
  WRS	
  to	
  begin	
  routing	
  operation
2a.	
  	
  WRS	
  converts	
  design	
  path	
  format	
  into	
  mechanical	
  motion
2b.	
  	
  WRS	
  feeds/lays/guides/prints	
  wire	
  along	
  the	
  design	
  path	
  
2c.	
  	
  WRS	
  constrains	
  the	
  wire	
  along	
  the	
  design	
  path	
  configuration	
  as	
  
	
  	
  	
  	
  	
  	
  the	
  wire	
  is	
  put	
  in	
  place
3.	
  	
  WRS	
  system	
  terminates	
  wire	
  at	
  the	
  end	
  of	
  the	
  wire	
  route	
  path
4.	
  	
  WRS	
  communicates	
  to	
  Operator	
  that	
  the	
  wire	
  route	
  is	
  complete
Basic	
  Flow 1.	
  	
  Operator	
  request	
  wire	
  type/size	
  for	
  harness	
  design
2.	
  	
  WRS	
  communicates	
  to	
  the	
  operator	
  what	
  wire	
  type/size	
  is	
  need	
  for	
  
	
  	
  	
  	
  	
  	
  the	
  desired	
  design
3.	
  	
  	
  WRS	
  provides	
  step	
  by	
  step	
  instructions	
  showing	
  operator	
  how	
  to	
  
	
  	
  	
  	
  	
  	
  load	
  wire
4.	
  	
  Operator	
  follows	
  steps	
  presented	
  and	
  prepares	
  the	
  WRS	
  to	
  
	
  	
  	
  	
  	
  	
  receive	
  the	
  wire
5.	
  	
  Operator	
  makes	
  the	
  wire	
  available	
  to	
  the	
  WRS	
  system
6.	
  	
  WRS	
  system	
  receives	
  wire	
  and	
  indicates	
  to	
  user	
  that	
  the	
  wire	
  is	
  
	
  	
  	
  	
  	
  	
  successfully	
  received
1.	
  	
  WRS	
  communicates	
  to	
  the	
  operator	
  that	
  the	
  wire	
  routing	
  process	
  
	
  	
  	
  	
  	
  	
  is	
  complete.
2.	
  	
  Operator	
  indicates	
  to	
  the	
  WRS	
  the	
  desire	
  to	
  remove	
  wire	
  from	
  
	
  	
  	
  	
  	
  	
  system
3.	
  	
  WRS	
  ensures	
  wire	
  is	
  securely	
  constrained	
  in	
  configured	
  route
4.	
  	
  WRS	
  maneuvers,	
  allowing	
  Operator	
  access	
  to	
  the	
  routed	
  wire	
  
5.	
  	
  WRS	
  releases	
  wire	
  constraints	
  as	
  necessary	
  to	
  allow	
  removal	
  of	
  
	
  	
  	
  	
  	
  	
  wire	
  without	
  losing	
  route	
  configuration
6.	
  	
  Operator	
  communicates	
  to	
  the	
  WRS	
  that	
  the	
  wire	
  is	
  successfully	
  
	
  	
  	
  	
  	
  	
  removed	
  and	
  the	
  WRS	
  is	
  clear	
  of	
  personnel	
  or	
  obstruction
7.	
  	
  WRS	
  system	
  maneuvers	
  back	
  to	
  operational	
  configuration
Basic	
  Flow
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 7    ~
Table 9-2 Complete list of WRS customer requirements
Table 9-3 Complete list of WRS derived requirements
Figure 9.1 Affinity diagram of customer requirements
Use	
  Case	
  Name 2.1	
  Receive	
  Input Parent	
  Use	
  Case	
  Name 2.1	
  Receive	
  Input
Use	
  Case	
  Description Wire	
  Routing	
  System	
  (WRS)	
  receives	
  input	
  from	
  operator Misuse	
  Case	
  ID 2.1.a	
  Workstation	
  Misuse
Actor System	
  Command	
  Operator	
   Misuse	
  Case	
  Description Operator	
  wants	
  to	
  perform	
  an	
  operation	
  that	
  is	
  not	
  displayed
Pre-­‐conditions WRS	
  is	
  in	
  a	
  state	
  of	
  standby	
  awaiting	
  input	
  from	
  Operator Actor Operator
Pre-­‐conditions WRS	
  is	
  in	
  a	
  state	
  of	
  standby	
  awaiting	
  input	
  from	
  Operator
Basic	
  Flow 1.	
  	
  WRS	
  communicates	
  to	
  Operator	
  what	
  current	
  state	
  of	
  system	
  is
2.	
  	
  WRS	
  presents	
  next	
  step	
  options	
  to	
  Operator
3.	
  	
  Operator	
  determines	
  most	
  applicable	
  next	
  step	
  of	
  desired	
  outcome
4.	
  	
  Operator	
  does	
  not	
  see	
  desired	
  option
5.	
  	
  Operator	
  returns	
  to	
  "main	
  menu"
6.	
  Operator	
  navigates	
  to	
  desired	
  input.
7.	
  	
  Operator	
  commands	
  WRS	
  to	
  perform	
  desired	
  next	
  operation
8.	
  	
  WRS	
  received	
  input	
  and	
  is	
  ready	
  to	
  performs	
  command
Post-­‐conditions WRS	
  has	
  successfully	
  received	
  desired	
  input	
  and	
  is	
  ready	
  to	
  perform	
  
command
Post-­‐conditions WRS	
  has	
  successfully	
  received	
  desired	
  input	
  and	
  is	
  ready	
  to	
  perform	
  
command
Misuse	
  Scenarios a.	
  	
  Workstation	
  Misuse
Basic	
  Flow 1.	
  	
  WRS	
  communicates	
  to	
  Operator	
  what	
  current	
  state	
  of	
  system	
  is
2.	
  	
  WRS	
  presents	
  next	
  step	
  options	
  to	
  Operator
3.	
  	
  Operator	
  determines	
  most	
  applicable	
  next	
  step	
  of	
  desired	
  outcome
4.	
  	
  Operator	
  commands	
  WRS	
  to	
  perform	
  desired	
  next	
  operation
5.	
  	
  WRS	
  received	
  input	
  and	
  is	
  ready	
  to	
  performs	
  command
Req. # Req. Origin Requirement Short Text Requirement Long Text
CR1 D2.OPERATOR.BD.01 Manual	
  activation	
  and	
  deactivation Operator	
  shall	
  be	
  provided	
  means	
  to	
  activate	
  and	
  deactivate	
  the	
  WRS	
  manually
CR2 D2.OPERATOR.BD.04.1 Means	
  to	
  remove	
  completed	
  product The	
  WRS	
  shall	
  provide	
  operator	
  means	
  to	
  remove	
  the	
  completed	
  product
CR3 D2.OPERATOR.BD.02.1 Uploaded	
  wire	
  route	
  path Operator	
  shall	
  be	
  provided	
  means	
  to	
  upload	
  wire	
  route	
  path	
  data	
  into	
  the	
  WRS	
  software
CR4 D2.OPERATOR.BD.02 User	
  Interface The	
  WRS	
  shall	
  provide	
  operator	
  a	
  graphical	
  user	
  interface
CR5 D2.SYSTEM.TD.04 Visual	
  and	
  oral	
  queues The	
  WRS	
  shall	
  include	
  visual	
  and	
  oral	
  queues	
  to	
  guide	
  operation
CR6 D2.SYSTEM.TD.11 Uses	
  CNC	
  routing	
  files The	
  WRS	
  shall	
  accept	
  CNC	
  routing	
  files
CR7 D2.SYSTEM.TD.08 Maintainable The	
  WRS	
  shall	
  be	
  capable	
  of	
  receiving	
  maintenance
CR8 D2.SYSTEM.TD.03 Routes	
  wire	
  in	
  3D	
  space The	
  WRS	
  shall	
  route	
  wire	
  in	
  three	
  dimensional	
  space
CR9 D2.SYSTEM.TD.06 Auto	
  shutoff The	
  WRS	
  shall	
  include	
  an	
  automatic	
  shutoff
CR10 D2.SYSTEM.TD.15 Provides	
  status	
  to	
  operator The	
  WRS	
  shall	
  provide	
  operational	
  status	
  to	
  operator
CR11 D2.SYSTEM.TD.01 Provide	
  hazard	
  protection The	
  WRS	
  shall	
  protect	
  bystanders	
  from	
  hazards	
  presented	
  by	
  moving	
  parts
CR12 D2.SYSTEM.TD.07 Modular	
   The	
  WRS	
  shall	
  be	
  modular	
  to	
  allow	
  for	
  future	
  expansion
CR13 D2.WIRE.CV.07 Limit	
  wire	
  waste The	
  wire	
  that	
  exists	
  outside	
  the	
  routed	
  envelope	
  shall	
  be	
  limited	
  to	
  a	
  designated	
  length
CR14 D2.WIRE.CV.03 Routes	
  wire	
  within	
  design	
  specifications The	
  WRS	
  shall	
  produce	
  routed	
  wire	
  that	
  meets	
  design	
  path	
  tolerance	
  specified	
  within	
  engineering	
  requirements
CR15 D2.WIRE.CV.06 Wires	
  can	
  be	
  grouped The	
  routed	
  wire	
  shall	
  be	
  capable	
  of	
  being	
  grouped	
  together	
  with	
  other	
  wires	
  routed	
  along	
  the	
  same	
  path
CR16 D2.UTILITY.KL.06 Electrically	
  grounded The	
  WRS	
  shall	
  be	
  electrically	
  grounded	
  to	
  comply	
  with	
  national,	
  state,	
  and	
  local	
  regulations
CR17 D2.UTILITY.KL.07 Surge	
  protection The	
  WRS	
  shall	
  incorporate	
  utility	
  surge	
  protection
CR18 D2.LIFE.AS.05.1 Components	
  must	
  fit	
  through	
  doorways The	
  WRS	
  shall	
  disassemble	
  to	
  fit	
  through	
  NFPA	
  standard	
  openings
CR19 D2.SUSTAINMENT.SM.01 Uses	
  commercial	
  software The	
  Wire	
  Routing	
  System	
  shall	
  use	
  existing	
  Commercial-­‐off-­‐the-­‐Shelf	
  (COTS)	
  software
CR20 D2.SUSTAINMENT.SM.04 Calibratable The	
  WRS	
  shall	
  incorporate	
  calibration	
  as	
  required	
  to	
  maintain	
  engineering	
  specifications
CR21 D2.UTILITY.KL.05 Manages	
  waste The	
  WRS	
  shall	
  manage	
  byproduct	
  waste
CR22 D2.UTILITY.KL.01 Powered	
  by	
  local	
  utilities The	
  WRS	
  shall	
  be	
  powered	
  by	
  local	
  power	
  utilities
WRS Customer Requirements
Req. # Cust. Req. Trace Requirement Short Text Requirement Long Text
DR22.1 CR22 Convert	
  Power Power	
  infusion	
  to	
  system	
  shall	
  be	
  distributed	
  within	
  standard	
  safety	
  parameters	
  of	
  the	
  power	
  source.
DR22.2 CR22 Distribute	
  Power The	
  WRS	
  shall	
  provide	
  Individual	
  electrical	
  components	
  with	
  the	
  appropriate	
  power
DR22.3 CR22 Operational	
  Conditions The	
  WRS	
  shall	
  provide	
  operational	
  environment	
  for	
  components
DR21.1 CR21 Provide	
  Ventilation WRS	
  shall	
  have	
  a	
  sub-­‐system	
  exhaust	
  ventilation	
  to	
  meet	
  quality	
  standards	
  dictated	
  by	
  EPA.
DR14.1 CR6 Translate	
  Design	
  to	
  Route The	
  WRS	
  shall	
  read	
  CNC	
  file	
  types	
  and	
  convert	
  into	
  mechanical	
  motion	
  to	
  implement	
  	
  wire	
  routing	
  designs
DR.8.1 CR4, CR14 Receive	
  Wire The	
  WRS	
  shall	
  receive	
  wire	
  based	
  upon	
  routed	
  wire	
  specifications
DR8.2 CR8 Support	
  Routed	
  Wire Routed	
  wire	
  shall	
  remain	
  in	
  routed	
  configuration	
  within	
  design	
  tolerances	
  until	
  further	
  processing
DR8.3 CR14, CR15 Deploy	
  Wire The	
  WRS	
  shall	
  deploy	
  wire	
  along	
  design	
  path	
  during	
  mechanical	
  motion
DR7.1 CR7 Receive	
  Lubricant The	
  WRS	
  components	
  shall	
  be	
  capable	
  to	
  receive	
  lubricant
DR19.1 CR7, CR19 Programmable	
  Software the	
  WRS	
  software	
  package	
  shall	
  accept	
  prescribed	
  updates
DR7.2 CR7, CR12 Replaceable	
  Interchangeable	
  Parts The	
  WRS	
  shall	
  utilize	
  commercially	
  available	
  hardware	
  to	
  prevent	
  obsolescence
DR12.1 CR12, CR18 Mechanically	
  &	
  Electrically	
  Separable The	
  WRS	
  shall	
  incorporate	
  reusable	
  connections	
  between	
  components
DR21.2 CR21 Utilize	
  Recyclable	
  Material The	
  WRS	
  shall	
  adhere	
  to	
  environmental	
  sustainment	
  regulations
WRS Derived Requirements
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 8    ~
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    2 9    ~
Figure 9.2 Functional Tree Diagram
9.2 Appendix	
  II	
  Requirements	
  Analysis	
  
Table 9-4 WRS evaluation criteria matrix
Wire Routing System
1 Utility
2 Operation
3 Sustainment
1.1 Receive Power
1.1.1 Convert Power
1.1.2 Surge Protect
1.1.3 Ground Power
1.1.4 Distribute Power
1.2 Ventilate
Components
1.2.1 Cool Electronics
1.2.2 Remove Exhaust/
Particulate
2.1 Receive Input
2.1.1 Receive Wire Path
Design
2.1.1.1 Translate Design
to Route
2.1.2 Receive Wire
2.1.3 Receive Start/
Stop
2.2 Route Wire
2.2.1 Navigate Wire in
3D Space
2.2.3 Support Routed
Wire
2.2.2 Deploy Wire
2.2.1.1 Deliver Wire
along path
2.2.1.2 Allow for
Grouping
2.3 Produce Output
3.1 Maintainable
Functionality
3.1.1 Capable of
Receiving Service
3.1.2 Capable of
Receiving Repairs
3.1.2.1 Replaceable
Interchangeable Parts
3.1.1.1 Calibration
Capable
3.1.1.2 Capable of
Receiving Lubricant
3.1.1.3 Programmable
Software
3.2 Transportable
Components
3.2.1 Decomposable
Modules
3.2.1.1 Mechanically &
Electrically Separable
3.3 Environmentally
Friendly
3.3.1 Utilize Recyclable
Material
3.3.2 Use Reusable
Parts
2.3.1 Communicate
Messages
2.3.2 Accommodate
Removal of Wire
2.3.3 Remove Debris/
Waste
2.1.3.1 Activate Device
2.1.3.2 Deactivate
Device
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 0    ~
Table 9-5 WRS requirements prioritization matrix
Evaluation
Criteria
Options
Increase
Accuracy /
Repeatability
Simplify User
Operation
Increase
Reliability
Lower
Operating
Cost
Use Existing
Technology
Total across
rows
% Grand total
A. Powered by local utilities [20] 0.0128 0.0012 0.0237 0.0160 0.0062 0.0599 0.0627
B. Provide hazard protection [10] 0.0063 0.0038 0.0138 0.0184 0.0029 0.0451 0.0473
C. Provide routed wire to operator [2] 0.0165 0.0150 0.0033 0.0229 0.0051 0.0628 0.0658
D. System is Transportable [18] 0.0059 0.0044 0.0088 0.0031 0.0025 0.0247 0.0259
E. Maintainable components [7] 0.0465 0.0078 0.0442 0.0117 0.0063 0.1166 0.1221
F. Receive operator inputs[1] 0.0065 0.0072 0.0135 0.0083 0.0041 0.0397 0.0416
G. Receive wire route path from operator [3] 0.0349 0.0177 0.0079 0.0265 0.0081 0.0951 0.0996
H. User Interface [4] 0.0167 0.0221 0.0262 0.0407 0.0155 0.1211 0.1269
I. Provides status to operator [9] 0.0159 0.0152 0.0279 0.0158 0.0039 0.0787 0.0824
J. Uses commercial software [16] 0.0076 0.0027 0.0100 0.0122 0.0266 0.0592 0.0620
K. Route wire within design specifications [22] 0.0930 0.0012 0.0118 0.0049 0.0041 0.1150 0.1205
L. Wires can be grouped [13] 0.0408 0.0091 0.0026 0.0279 0.0018 0.0822 0.0861
M. Manages waste [19] 0.0074 0.0073 0.0027 0.0279 0.0093 0.0546 0.0572
Column Total 0.3109 0.1146 0.1964 0.2364 0.0965 0.9548 1.0000
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 1    ~
9.3 Appendix	
  III	
  Architecture	
  
Figure 9.3 Interrelationship Digraph
	
  
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 2    ~
Figure 9.4 Hatley–Pirbhai modeling
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 3    ~
9.4 Appendix	
  IV	
  V	
  &	
  V	
  
Table 9-6 Four (4) Phase Test Plan
Phase Description Strategy/Approach Scope
1
Individual Component
Testing/ Firmware AoA
Research & Sample, Compare
configurations of hardware components of
various programming languages
Requirements Design Development(RDD) Behavior model,
Default Behavior, Code hours Estimation Determine the
capabilities limitations of available options for Phase 2 & 3
selections
2
Subsystem Level
Hardware integration
testing
Build subsystems based on the Phase 1
recommendations
Interoperability of firm/middleware and PLCs, Ensure that
the pieces work well in the suggested arrangement and
determine alternatives where necessary, Firmware
teardown
3
Subsystem Level
Software integration
testing Define boundaries and error states
Interoperability of firm/middleware and software, RDD Test
In Process Review(does the code match the expected
behavior model, bug fix, Rigorous code walkthrough,
Ensure that the programs work well in the suggested
arrangement and determine alternatives where necessary
4 Prototype Test
Final Validation/ Rework as needed per
customer input
Integrate Phase 2&3 subsystems and Identify
Deficiencies/The pieces fit together-do they work together
4.1
Mechanical Interface/
Interference Tests
Interface Analysis & Testing,
Structural Testing Verify mechanical interfaces do not become interferences
4.2 Operational Testing
Fault Failure Insertion, Functional (black box)
testing
when an error is encountered/produced does the system
react as intended unforeseen errors/reactions?
4.3 Quality testing Top-Down Testing, Fatigue Testing
Real world simulations, Routed wire tolerance and
repetition
4.4 Rework Bottom-Up Testing Apply Necessary Corrections
4.5 Retest Restart Phase 4
5 Future Integrations Add on features & software updates Beyond the 2yr scope of Baseline Model development
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 4    ~
Table 9-7 Review Gate Table
PHASE ENTRY GATE SCOPE PHASE EXIT GATE SCOPE
Review Gate 1.1
Determine if we are ready to begin
component procurement and testing Review Gate 1.2
Determine that previous phase was successful and
completed to allow project to move forward,
STAKEHOLDER INPUT REQUIRED
Review Gate 2.1
Determine if we are ready to begin
component integration and testing Review Gate 2.2
Determine that previous phase was successful and
completed to allow project to move forward
Review Gate 3.1
Determine if we are ready to begin
system integration and testing Review Gate 3.2
Determine that previous phase was successful and
completed to allow project to move forward,
STAKEHOLDER INPUT REQUIRED
Review Gate 4.1
Determine if we are ready to begin
system operational testing
Review Gate 4.2
Determine that mechanical
subsystems are appropriate
Review Gate 4.3
Determine that mechanical
subsystems are properly limited by
operatin system
Review Gate 4.4
Determine that software controls are
properly limited, hardware properly
monitored Review Gate 4.5
Determine complete or repeat,
STAKEHOLDER INPUT REQUIRED
Review Gate 4.6
Determine the scope and objective of
necessary rework
Review Gate 4.7 Determine success of rework Review Gate 4.1a Refer to Review Gate 4.1
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 5    ~
Table 9-8 Validation Matrix
TRACE	
  ID	
   TEST	
  PLAN	
   	
  	
  
Decomposed	
  
Function	
  
Customer	
  
Requirement	
  
Derived	
  
Requirement	
  
	
  
Phase	
  1	
  
	
  
Phase	
  2	
  
	
  
Phase	
  3	
  
	
  
Phase	
  4	
  
1	
  
	
   	
   ✓ ✓
1.1	
  
	
   	
  
✓ ✓
1.1.1	
   CR22	
   DR22.1	
   ✓
1.1.2	
   CR17,	
  CR9,	
  CR11	
  
	
   ✓
1.1.3	
   CR16,	
  CR11	
  
	
   ✓
1.1.4	
   CR22	
   DR22.2	
   ✓ ✓ ✓
1.2	
  
	
   	
   ✓ ✓
1.2.1	
   CR22	
   DR22.3	
   ✓ ✓ ✓
1.2.2	
   CR21	
   DR21.1	
   ✓ ✓
2	
  
	
   	
   ✓
2.1	
  
	
   	
   ✓ ✓
2.1.1	
   CR3	
  
	
   ✓
2.1.1.1	
   CR6	
   DR14.1	
   ✓
2.1.2	
   CR4,	
  CR24	
   DR.8.1	
   ✓ ✓ ✓
2.1.3	
   CR1	
  
	
  
✓ ✓
2.1.3.1	
   CR1	
  
	
   ✓
2.1.3.2	
   CR1,	
  CR9	
  
	
   ✓
2.2	
  
	
   	
   ✓ ✓
2.2.13	
   CR8,	
  CR14	
  
	
   ✓ ✓ ✓
2.2.1.1	
   CR15,	
  CR14	
  
	
  
✓
2.2.1.2	
   CR15	
  
	
   ✓
2.2.2	
   CR8	
   DR8.2	
   ✓ ✓
2.2.3	
   CR14,	
  CR15	
   DR8.3	
   ✓ ✓
2.3	
  
	
   	
   ✓
2.3.1	
   CR4,	
  CR5,	
  CR10	
  
	
  
✓
2.3.2	
   CR2	
  
	
   ✓ ✓
2.3.3	
   CR21,	
  CR13	
  
	
   ✓ ✓
3	
  
	
   	
   ✓
3.1	
  
	
   	
   ✓
3.1.1	
   CR7	
  
	
  
✓
3.1.1.1	
   CR20,	
  CR7	
  
	
   ✓ ✓
3.1.1.2	
   CR7	
   DR7.1	
   ✓ ✓
3.1.1.3	
   CR7,	
  CR19	
   DR19.1	
   ✓ ✓ ✓
3.1.2	
   CR7	
  
	
   ✓ ✓
3.1.2.1	
   CR7,	
  CR12	
   DR7.2	
   ✓ ✓
3.2	
  
	
   	
   ✓
3.2.1	
   CR12,	
  CR18	
  
	
   ✓ ✓
3.2.1.1	
   CR12,	
  CR18	
   DR12.1	
   ✓
3.3	
  
	
   	
  
✓
3.3.1	
   CR21	
   DR21.2	
   ✓
3.3.2	
   CR21	
   DR21.3	
   ✓ ✓
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 6    ~
Table 9-9 Compliance Matrix
Requirement	
  Source	
   Category	
   Verification	
  Method	
  
Verification	
  Status	
  
(NV	
  =	
  not	
  verified,	
  
V	
  =	
  verified)	
  
Acceptance	
  Criteria	
  
Customer	
  Requirement	
  
Source	
  
Functional	
  
Identifier	
  
Derived	
  
Requirement	
  
Identifier	
  
Customer	
  
Requirement	
  
Identifier	
  
NFPA	
  70B;	
  OSHA	
  29	
  CFR	
  
1910.	
  269;	
  IEEE	
  67-­‐1990	
   Utilities	
  	
   Test,	
  Inspection	
   NV	
  
per	
  NFPA,	
  OSHA,	
  IEEE	
  
criteria	
   D2.UTILITY.KL.01	
   1.1.1	
   DR22.1	
   CR22	
  
NFPA	
  70.285;	
  OSHA	
  29	
  CFR	
  
1910.269;	
  IEEE	
  1-­‐1986	
   Utilities	
  	
   Test,	
  Inspection	
   NV	
  
per	
  NFPA,	
  OSHA,	
  IEEE	
  
criteria	
   D2.UTILITY.KL.06	
   1.1.2	
   DR22.2	
   CR16	
  
NFPA	
  99;	
  OSHA	
  29	
  CFR	
  
1910.269;	
  IEEE	
  32-­‐1972	
   Utilities	
  	
   Inspection	
   NV	
  
per	
  NFPA,	
  OSHA	
  
criteria	
   D2.UTILITY.KL.07	
   1.1.3	
   DR22.2	
   CR17	
  
OSHA	
  1910.335	
   Utilities	
  	
   Test,	
  Inspection	
   NV	
   per	
  OSHA	
  criteria	
   D2.SYSTEM.TD.06	
   1.1.4	
   DR22.2	
   CR12	
  
IEEE	
  389-­‐1996	
   Operations	
   Calculation,	
  Test	
   NV	
   per	
  IEEE	
  criteria	
   D2.UTILITY.KL.01	
   1.2.1	
   DR22.3	
   CR22	
  
OSHA	
  1926.416	
   Operations	
  
Analyses,	
  Test,	
  
Inspection	
   NV	
  
As	
  stated	
  in	
  
requirement	
  text	
   D2.SYSTEM.TD.01	
   1.2.2	
   NA	
   CR11	
  
Stakeholder	
  Defined	
   Operations	
   Calculation,	
  Test	
   NV	
  
As	
  stated	
  in	
  
requirement	
  text	
   D2.SYSTEM.TD.11	
   2.1.1	
   DR14.1	
   CR6	
  
OSHA	
  1910.307	
   Operations	
  
Design	
  Review	
  of	
  
calculations,	
  Test	
   NV	
  
As	
  stated	
  in	
  
requirement	
  text	
   D2.SYSTEM.TD.15	
   2.1.2	
   NA	
   CR10	
  
Stakeholder	
  Defined	
   Operations	
  
Design	
  Review	
  of	
  
calculations,	
  Test	
   NV	
  
Calculation	
  specifies	
  
Req	
  2.1.2	
  as	
  input	
  
D2.WIRE.CV.03	
  
D2.WIRE.CV.06	
   2.2.1	
   DR8.3	
  
CR14	
  
CR15	
  
Stakeholder	
  Defined	
  	
   Operations	
   Design	
  Review,	
  Test	
   NV	
  
As	
  stated	
  in	
  
requirement	
  text	
   Req.	
  D2.SYSTEM.TD.15	
   2.3.1	
   NA	
   CR10	
  
Stakeholder	
  Defined	
  	
   Operations	
   Analyses,	
  Test	
   NV	
  
As	
  stated	
  in	
  
requirement	
  text	
   Req.	
  D2.	
  OPERATOR.BD.04.1	
   2.3.2	
   DR21.1	
   CR2	
  
EPA	
  NESHAP	
   Operations	
   Inspection	
   NV	
   per	
  NESHAP	
  criteria	
   Req.	
  D2.UTILITY.KL.05	
   2.3.3	
   DR21.2	
   CR21	
  
NFPA	
  80	
   Sustainment	
   Test,	
  Inspection	
  	
   NV	
   per	
  NFPA	
  criteria	
  	
   Req.	
  D2.LIFE.AS.05.1	
   3.2.1	
   DR12.1	
   CR18	
  
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 7    ~
Table 9- 10 WRS
Traceability
Functional Decomposition
Original Customer
Requirement
Derived
Requirements
1.1.1 Convert Power CR22 DR22.1
1.1.2 Surge Protect CR17, CR9, CR11
1.1.3 Ground Power CR16, CR11
1.1.4 Distribute Power CR22 DR22.2
1.2.1 Cool Electronics CR22 DR22.3
1.2.2 Remove Exhaust/Particulate CR21 DR21.1
2.1.1 Receive Wire Path Design CR3
2.1.1.1 Translate Design to Route CR6 DR14.1
2.1.2 Receive Wire CR8 DR.8.1
2.1.3 Receive Start/Stop CR1
2.1.3.1 Activate Device CR1
2.1.3.2 Deactivate Device CR1, CR9
2.2.1 Navigate Wire in 3D Space CR8, CR14
2.2.1.1 Deliver Wire along path CR15, CR14
2.2.1.2 Allow for Grouping CR15
2.2.3 Support Routed Wire CR8 DR8.2
2.2.2 Deploy Wire CR14, CR15 DR8.3
2.3.1 Communicate Messages CR4, CR5, CR10
2.3.2 Accommodate Removal of Wire CR2
2.3.3 Remove Debris/Waste CR21, CR13
3.1.1 Capable of Receiving Service CR7
3.1.1.1 Calibration Capable CR20, CR7
3.1.1.2 Capable of Receiving Lubricant CR7 DR7.1
3.1.1.3 Programmable Software CR7, CR19 DR19.1
3.1.2 Capable of Receiving Repairs CR7
3.1.2.1 Replaceable Interchangeable Parts CR7, CR12 DR7.2
3.2.1 Decomposable Modules CR12, CR18
3.2.1.1 Mechanically & Electrically Separable CR12, CR18 DR12.1
3.3.1 Utilize Recyclable Material CR21 DR21.2
3.3.2 Use Reusable Parts CR21 DR21.3
1.2 Ventilate Components
1.1 Receive Power
1 Utility
Wire Routing System Requirements Traceability
3.3 Environmentally Friendly
3.2 Transportable Components
3.1 Maintainable Functionality
3 Sustainment
2.3 Produce Output
2.2 Route Wire
2.1 Receive Input
2 Operation
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 8    ~
9.5 Appendix	
  V	
  Market	
  Research	
  
Table 9-11 Technology Impact Matrices
Receive	
  Wire	
  Path	
  Design	
  TIM	
  
	
   	
   	
   	
   	
  Ref	
  2.1.1	
  	
   	
  	
   Technology	
  
	
  
MOE	
  
%	
  Relative	
  
Importance	
  Weight	
  
Wired	
  Network	
   USB	
  2.0/3.0	
   Cloud	
  Based	
   Totals	
  
	
  Accuracy/Repeatability	
   0.31	
   6	
   9	
   6	
   21	
  
	
  Simplified	
  User	
  Operation	
   0.1	
   9	
   9	
   6	
   27	
  
	
  Increased	
  Reliability	
   0.2	
   9	
   6	
   3	
   21	
  
	
  Low	
  Operating	
  Cost	
  	
   0.28	
   9	
   9	
   6	
   3	
  
	
  Technology	
  Readiness	
  Level	
   0.11	
   9	
   9	
   9	
   27	
  
	
  	
  	
   Weighted	
  Sums	
   8.07	
   8.4	
   5.73	
   22.2	
  
	
  
	
  
Total	
  Percent	
  Weight	
   36%	
   38%	
   26%	
   100%	
  
	
  
	
   	
   	
   	
   	
   	
   	
  Receive	
  Wire	
  TIM	
  
	
   	
   	
   	
   	
   	
  Ref	
  2.1.2	
   	
  	
   Technology	
   	
  	
  
MOE	
  
%	
  Relative	
  
Importance	
  Weight	
  
Gear	
  Wheel	
  
Straightener	
  
Bearing	
  Wheel	
  
Straightener	
  
Conveyorless	
   Crank	
  Wheel	
   Totals	
  
Accuracy/Repeatability	
   0.31	
   9	
   9	
   6	
   3	
   27	
  
Simplified	
  User	
  Operation	
   0.1	
   9	
   9	
   9	
   3	
   30	
  
Increased	
  Reliability	
   0.2	
   9	
   9	
   6	
   1	
   25	
  
Low	
  Operating	
  Cost	
  	
   0.28	
   7	
   6	
   9	
   1	
   23	
  
Technology	
  Readiness	
  Level	
   0.11	
   9	
   9	
   9	
   9	
   36	
  
	
  	
   Weighted	
  Sums	
   8.44	
   8.16	
   7.77	
   2.9	
   27.27	
  
	
  
Total	
  Percent	
  Weight	
   31%	
   30%	
   28%	
   11%	
   100%	
  
	
   	
   	
   	
   	
   	
   	
  Route	
  Wire	
  TIM	
  
	
   	
   	
   	
   	
   	
  Ref	
  2.2	
   	
  	
   Technology	
  	
   	
  	
  
	
  
MOE	
  
%	
  Relative	
  
Importance	
  Weight	
  
Belt	
  Driven	
   	
  Linear	
  Ball	
  Slide	
  
Manual	
  Peg	
  
Board	
  
Totals	
  
	
  Accuracy/Repeatability	
   0.31	
   6	
   9	
   3	
   18	
  
	
  Simplified	
  User	
  Operation	
   0.1	
   6	
   6	
   1	
   13	
  
	
  Increased	
  Reliability	
   0.2	
   6	
   6	
   1	
   13	
  
	
  Low	
  Operating	
  Cost	
  	
   0.28	
   9	
   9	
   1	
   19	
  
	
  Technology	
  Readiness	
  Level	
   0.11	
   9	
   9	
   9	
   27	
  
	
  	
  	
   Weighted	
  Sums	
   7.17	
   8.1	
   2.5	
   17.77	
  
	
  
	
  
Total	
  Percent	
  Weight	
   40%	
   46%	
   14%	
   100%	
  
	
  
	
   	
   	
   	
   	
   	
   	
  
	
   	
   	
   	
   	
   	
   	
  Receive	
  Input	
  TIM	
  
	
   	
   	
   	
   	
   	
  Ref	
  2.1	
   	
  	
   Technology	
   	
  	
  
MOE	
  
%	
  Relative	
  
Importance	
  Weight	
  
Form	
  Based	
  	
   Capacitive	
  Touch	
  HMI	
   Command	
  Line	
   WIMP/GUI	
   Totals	
  
Accuracy/Repeatability	
   0.31	
   9	
   6	
   9	
   6	
   30	
  
Simplified	
  User	
  Operation	
   0.1	
   9	
   3	
   1	
   9	
   22	
  
Increased	
  Reliability	
   0.2	
   9	
   1	
   9	
   9	
   28	
  
Low	
  Operating	
  Cost	
  	
   0.28	
   3	
   9	
   1	
   6	
   19	
  
Technology	
  Readiness	
  Level	
   0.11	
   9	
   3	
   9	
   6	
   27	
  
	
  
Weighted	
  Sums	
   7.32	
   5.21	
   5.96	
   6.9	
   25.39	
  
	
  
Total	
  Percent	
  Weight	
   29%	
   21%	
   23%	
   27%	
   100%	
  
	
   	
   	
   	
   	
   	
   	
  Accommodate	
  Removal	
  of	
  Wire	
  TIM	
  
	
   	
   	
   	
   	
  Ref	
  2.3.2	
   	
  	
   Technology	
   	
  	
  
	
   	
  
MOE	
  
%	
  Relative	
  
Importance	
  Weight	
  
Operator	
  Based	
  
Modular	
  Equipment	
  
Mechatronics	
   Totals	
  
	
   	
  Accuracy/Repeatability	
   0.31	
   3	
   9	
   12	
  
	
   	
  Simplified	
  User	
  Operation	
   0.1	
   6	
   9	
   15	
  
	
   	
  Increased	
  Reliability	
   0.2	
   6	
   6	
   12	
  
	
   	
  Low	
  Operating	
  Cost	
  	
   0.28	
   1	
   9	
   10	
  
	
   	
  Technology	
  Readiness	
  Level	
   0.11	
   9	
   6	
   15	
  
	
   	
  
	
  
Weighted	
  Sums	
   3.34	
   8.07	
   11.41	
  
	
   	
  
	
  
Total	
  Percent	
  Weight	
   29%	
   71%	
   100%	
  
	
   	
  
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    3 9    ~
Table 9-12 Technology Options
Ref.	
  1.1	
  Technology	
  Options	
  
	
   	
   	
   	
   	
  
	
  
Ref.	
  1.1	
  Power	
  Supply	
  Technology	
  
Technology	
  Attribute	
   Induction	
  Motor	
   Brushless	
  Motor	
  
Brushed	
  Universal	
  
Motor	
  
Natural	
  Gas	
   Solar	
  
Standard	
  US	
  
Electrical	
  Receptacle	
  
Control	
  Requirement	
   Optional	
   Always	
  	
   Optional	
   Always	
   Always	
   None	
  
Typical	
  Drive	
   AC	
   DC	
   DC	
   N/A	
   N/A	
   AC	
  
Maintenance	
   None	
  	
   None	
   Periodic	
   Periodic	
   Periodic	
   None	
  
Efficiency	
  	
   High	
   High	
   Moderate	
   High	
   High	
   Moderate	
  
Manual	
  
Activation/Deactivation	
  
Yes	
   Yes	
   Yes	
   Yes	
   Yes	
   Yes	
  
Power	
  Factor	
   Low/Moderate	
  (0.5-­‐0.95)	
   N/A	
   Moderate	
  (0.94)	
   N/A	
   N/A	
   Moderate	
  (0.9)	
  
Accuracy/Repeatability	
   High	
   High	
   High	
   High	
   Varies	
   Moderate/High	
  
Simplified	
  User	
  Operation	
   Yes	
   Yes	
   Yes	
   Yes	
   Yes	
   Yes	
  
Reliability	
   High	
   Moderate/High	
   High	
   Moderate/High	
   Varies	
   Varies	
  
Cost	
  	
   Low	
   High	
   Moderate	
  	
   Low	
   High	
   Low	
  
Existing	
  Technology	
   Yes	
   Yes	
   Yes	
   Developing	
   Developing	
   Yes	
  
Technology	
  Readiness	
  Level	
   9	
   9	
   9	
   3	
   5	
   9	
  
	
   	
   	
   	
   	
   	
   	
  Ref.	
  1.2.2	
  Technology	
  Options	
  
	
   	
  
	
   	
   	
  
	
  
Ref.	
  1.2.2	
  Remove	
  Exhaust/Particulate	
  Technology	
  
	
   	
   	
  Technology	
  Attribute	
  	
   Self	
  Dumping	
  Hopper	
   Manual	
   Ventilation	
  Exhaust	
  
	
   	
   	
  Effectiveness	
   Moderate/High	
   Low	
   High	
  
	
   	
   	
  Automated	
  Wire	
  Cutting	
   Varies	
   None	
   Varies	
  
	
   	
   	
  Maintenance	
   Moderate	
   High	
   Moderate	
  
	
   	
   	
  Conveyor	
  Belt	
  Specific	
   Varies	
   No	
   Varies	
  
	
   	
   	
  Accuracy/Repeatability	
   Low	
   Low	
   High	
  
	
   	
   	
  Simplified	
  User	
  Operation	
   Low	
   Low	
   High	
  
	
   	
   	
  Reliability	
   Low	
   Low	
   High	
  
	
   	
   	
  Cost	
  	
   Moderate/High	
   Low	
   Moderate/High	
  
	
   	
   	
  Existing	
  Technology	
   Yes	
   Yes	
   Yes	
  
	
   	
   	
  
Technology	
  Readiness	
  Level	
   9	
   6	
   9	
  
	
   	
   	
  
	
   	
   	
   	
   	
   	
   	
  Ref.	
  2.1.1.1	
  Technology	
  Options	
  
	
   	
   	
   	
   	
  
	
  
Ref.	
  2.1.1.1	
  Translate	
  Design	
  to	
  Route	
  Technology	
  
	
   	
  Technology	
  Attribute	
   SolidWORKS	
   Rhino	
   Pro/Engineer	
   LeapMotion	
  
	
   	
  
Commercial-­‐Off-­‐The-­‐Shelf	
   Yes	
   Yes	
   Yes	
   Yes	
  
	
   	
  3D	
  Capable	
   Yes	
   Yes	
   Yes	
   Yes	
  
	
   	
  
Augmented	
  Reality	
  Capable	
   No	
   No	
   No	
   Yes	
  
	
   	
  Maintenance	
   Low	
   Low	
   Low	
   Moderate	
  
	
   	
  Accuracy/Repeatability	
   High	
   High	
   High	
   Low/Moderate	
  
	
   	
  Simplified	
  User	
  Operation	
   Low	
   Low	
   Low/Moderate	
   Low/Moderate	
  
	
   	
  Reliability	
   High	
   High	
   High	
   Low/Moderate	
  
	
   	
  Cost	
  	
   High	
   High	
   High	
   High	
  
	
   	
  
Existing	
  Technology	
   Yes	
   Yes	
   Yes	
   Developing	
  
	
   	
  
Technology	
  Readiness	
  Level	
   9	
   9	
   9	
   3	
  
	
   	
  
Wire Routing System (WRS) Systems Engineering Management Plan
_____________________________________________________________________________
~    4 0    ~
Figure 9.5 Work Breakdown Structure
W2 Sys
Engineering
W2.2
Personnel
W2.2.1 Team
Lead
W2.2.2
Electrical Lead
W2.2.3
Mechanical
Lead
W2.2.4
Software Lead
W2.2.5 Drafter
W2.3 Research
& Development
W2.3.1Technol
ogy
W2.3.2
Procurement
W1 Project
Mgmt
W1.1
Personnel
W1.1.1 Project
Manager
W1.1.2
Financial
Planner
W1.1.3
Procurement
Manager
W1.1.4 Vendor
Oversight
W1.2 Facilities
W1.2.1
Property
W1.2.2
Equipment
W3 Interface
Systems
W3.1
Development
W3.2 Testing
of Software
Module
W3.2.1 Unit
Hardware Test
W3.2.2
Integration
W3.2.3 System
Test
W4 Control
System
W4.1 Control
Theory
Analysis
W4.2 Process
Control Software
Development
W4.2.1
Algorithm
Development
W4.2.2
Process
evaluation
W6
Management
Reserve
W6.1 Risk
mitigation
funding
W6.1.1 Quality
risk
W6.1.2 Cost
risk
W6.1.3
Schedule risk
W7 Assembly
and Test
W7.1 Facility
W7.1.1
Development of
facility requirements
W7.1.2 Facility
design
W7.1.3 Modify/
build to design
W7.2
Assembly and
test equipment
W7.2.1
Standard tools
W7.2.2
Specialty tools
W7.3
Assembly and
test personnel
W7.3.1 Internal
(WRS
personnel)
W7.3.2 External
(component
supplier SMEs)
W8
Sustainment
W8.1 Develop
maintenance
manuals
W8.1.1 Recommended
maintenance schedules
W8.1.2
Maintenance
procedures
W8.2 Develop
repair manuals
W8.2.1 Recommended
spare parts list and
quantities
W8.2.2 Repair
procedures
W8.3 Develop
training
curriculum
W8.3.1 Initial live
skills training and
certification
W8.3.2 Refresher
training and
recertification
W8.4
Sustainment
team
W8.4.1 Update
manuals
W8.4.2 Ensure
availability of
parts
W8.4.3 Update
training
W5 Mechanical
System
W5.1 Design
hardware
components
W5.1.1 Wire
deposit
hardware
W5.1.2 Wire
capture
hardware
W5.1.3 Wire
handling
hardware
W5.1.4 Utility
hardware
W5.1.6 Build
hardware
components
W5.1.7 Wire
deposit
hardware
W5.1.8 Wire
capture
hardware
W5.1.9 Wire
handling
hardware
W5.1.10 Utility
hardware
W5.2 V&V
W5.2.1 Design
V&V
W5.2.2 Build
V&V
W5.3
Component
Integration
W5.3.1 Design
of integration
points
W5.3.2
Interface
W5.3.3 Control
W5.3.4
Mechanical
W5.3.5
Subcontract/
vendor systems
W5.4
Coordination of
integration design
W5.4.1 Internal
coordination
W5.4.2
External
coordination
W1 Project
Mgmt
W2 Sys
Engineering
W3 Interface
Systems
W4 Control
System
W5 Mechanical
System
W6
Management
Reserve
W7 Assembly
and Test
W8
Sustainment
W1.1
Personnel
W1.1.1 Project
Manager
W1.1.2
Financial
Planner
W1.1.3
Procurement
Manager
W1.1.4 Vendor
Oversight
W1.2 Facilities
W1.2.1
Property
W1.2.2
Equipment
W2.2
Personnel
W2.2.1 Team
Lead
W2.2.2
Electrical Lead
W2.2.3
Mechanical
Lead
W2.2.4
Software Lead
W2.2.5 Drafter
W2.3 Research
& Development
W2.3.1Technol
ogy
W2.3.2
Procurement
W3.1
Development
W3.2 Testing
of Software
Module
W3.2.1 Unit
Hardware Test
W3.2.2
Integration
W3.2.3 System
Test
W4.1 Control
Theory
Analysis
W4.2 Process
Control Software
Development
W4.2.1
Algorithm
Development
W4.2.2
Process
evaluation
W5.1 Design
hardware
components
W5.1.1 Wire
deposit
hardware
W5.1.2 Wire
capture
hardware
W5.1.3 Wire
handling
hardware
W5.1.4 Utility
hardware
W5.1.6 Build
hardware
components
W5.1.7 Wire
deposit
hardware
W5.1.8 Wire
capture
hardware
W5.1.9 Wire
handling
hardware
W5.1.10 Utility
hardware
W5.2 V&V
W5.2.1 Design
V&V
W5.2.2 Build
V&V
W5.3
Component
Integration
W5.3.1 Design
of integration
points
W5.3.2
Interface
W5.3.3 Control
W5.3.4
Mechanical
W5.3.5
Subcontract/
vendor systems
W5.4
Coordination of
integration design
W5.4.1 Internal
coordination
W5.4.2
External
coordination
W6.1 Risk
mitigation
funding
W6.1.1 Quality
risk
W6.1.2 Cost
risk
W6.1.3
Schedule risk
W7.1 Facility
W7.1.1
Development of
facility requirements
W7.1.2 Facility
design
W7.1.3 Modify/
build to design
W7.2
Assembly and
test equipment
W7.2.1
Standard tools
W7.2.2
Specialty tools
W7.3
Assembly and
test personnel
W7.3.1 Internal
(WRS
personnel)
W7.3.2 External
(component
supplier SMEs)
W8.1 Develop
maintenance
manuals
W8.1.1 Recommended
maintenance schedules
W8.1.2
Maintenance
procedures
W8.2 Develop
repair manuals
W8.2.1 Recommended
spare parts list and
quantities
W8.2.2 Repair
procedures
W8.3 Develop
training
curriculum
W8.3.1 Initial live
skills training and
certification
W8.3.2 Refresher
training and
recertification
W8.4
Sustainment
team
W8.4.1 Update
manuals
W8.4.2 Ensure
availability of
parts
W8.4.3 Update
training
WRS

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Wire Routing System

  • 1. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1   ~ Wire Routing System (WRS) Systems Engineering Management Plan (SEMP) 5 October 2015
  • 2. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2   ~ Document Control Created By: Name: Title: Date: Brian Davidson Project Manager 23-Sep-15 Theresa D’Amore Deputy Project Manager 23-Sep-15 Chad Vance Systems Engineer, Integration 23-Sep-15 Andrew Schuettpelz Systems Engineer, SME 23-Sep-15 Kyle Lopez Systems Engineer, IT 23-Sep-15 Sachin Mehta Systems Engineer, V&V 23-Sep-15 Reviewed By: Name: Date: 2-Oct-15
  • 3. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3   ~ Table of Contents 1   SEMP / Project Overview.................................................................................................. 7   1.1   Need Statement........................................................................................................... 7   1.2   Project Structure ......................................................................................................... 9   2   Business Case .................................................................................................................... 9   3   Requirements Development Process ............................................................................... 10   3.1   Customer Requirements............................................................................................ 10   3.2   Derived Requirements .............................................................................................. 12   3.3   Requirements Analysis and Prioritization ................................................................ 13   4   System Architectures....................................................................................................... 14   4.1   Functional Analysis .................................................................................................. 14   4.1.1   Functional Architecture Description.................................................................. 14   4.2   Concept Exploration................................................................................................. 14   4.3   Architecture & Design Specifications ...................................................................... 15   4.3.1   Technology Market Survey ............................................................................... 15   4.3.2   Physical Architecture......................................................................................... 17   4.3.3   Architecture Documentation.............................................................................. 18   4.3.4   Architecture Quality Attributes ......................................................................... 18   5   System Verification and Validation................................................................................. 18   6   Design Model................................................................................................................... 20   7   Project Summary ............................................................................................................. 22   7.1   Work Breakdown Structure...................................................................................... 22   Project Management WBS ................................................................................................ 22   Systems Engineering WBS................................................................................................ 23   Interface Systems WBS..................................................................................................... 23   Control System WBS......................................................................................................... 23   Mechanical System WBS .................................................................................................. 23   Management Reserve WBS............................................................................................... 23   Assembly and Test WBS................................................................................................... 23   Sustainment WBS.............................................................................................................. 23   7.2   Project Plan............................................................................................................... 24   7.3   Risk Management..................................................................................................... 24   8   Lifecycle Management Plan ............................................................................................ 24   8.1   Deployment Plan ...................................................................................................... 24   8.2   Support Plan.............................................................................................................. 24   8.3   Cost Estimates .......................................................................................................... 24   9   Appendices ...................................................................................................................... 25   9.1   Appendix I Requirements......................................................................................... 25   9.2   Appendix II Requirements Analysis......................................................................... 29   9.3   Appendix III Architecture......................................................................................... 31   9.4   Appendix IV V & V ................................................................................................. 33   9.5   Appendix V Market Research .................................................................................. 38  
  • 4. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   4   ~ List of Tables Table 4-1 First and second place technology options................................................................... 16   Table 4-2 Technology Compatibility Matrix................................................................................ 17   Table 4-3 Physical Architecture Alternatives............................................................................... 18   Table 9-1 Use and misuse case scenarios based upon the use case diagram................................ 25   Table 9-2 Complete list of WRS customer requirements............................................................. 27   Table 9-3 Complete list of WRS derived requirements................................................................ 27   Table 9-4 WRS evaluation criteria matrix.................................................................................... 29   Table 9-5 WRS requirements prioritization matrix ...................................................................... 30   Table 9-6 Four (4) Phase Test Plan............................................................................................... 33   Table 9-7 Review Gate Table ....................................................................................................... 34   Table 9-8 Validation Matrix ......................................................................................................... 35   Table 9-9 Compliance Matrix....................................................................................................... 36   Table 9-10 WRS Traceability....................................................................................................... 37   Table 9-11 Technology Impact Matrices...................................................................................... 38   Table 9-12 Technology Options ................................................................................................... 39  
  • 5. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   5   ~ List of Figures Figure 1.1- Wire Harness _______________________________________________________ 7   Figure 1.2 - Form Board ________________________________________________________ 7   Figure 1.3 Wire Harness Fabrication Process________________________________________ 8   Figure 1.4 Wire Routing System Model____________________________________________ 9   Figure 3.1  WRS  use  case  diagram_______________________________________________ 11   Figure 3.2 Use case for route wire _______________________________________________ 11   Figure 3.3  Derived  Requirements  traceability  back  to  Customer  Require______________ 13   Figure 4.1 Ranked Architecture Alternatives _______________________________________ 15   Figure 6.1 Hybrid Communication-Sequence Diagram _______________________________ 21   Figure 6.2 WRS boundary diagram ______________________________________________ 22   Figure 9.1 Affinity diagram of customer requirements _______________________________ 27   Figure 9.2 Functional Tree Diagram______________________________________________ 29   Figure 9.3 Interrelationship Digraph______________________________________________ 31   Figure 9.4 Hatley–Pirbhai modeling _____________________________________________ 32   Figure 9.5 Work Breakdown Structure____________________________________________ 40  
  • 6. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   6   ~ List of Acronyms AND Activity Network Diagram COTS Commercial Off-the-Shelf CR Customer Requirements ConOps Concept of Operations DRCM Design Requirements Compliance Matrix EC Engineering Characteristics EPA Environmental Protection Agency FFBD Functional Flow Block Diagram ICD Interface Control Document ID Interrelationship Digraph IEEE Institute of Electrical and Electronics Engineers INCOSE International Council On Systems Engineering IPD Integrated Product Team MMA Morphological Matrix of Alternatives MOE Measures of Effectiveness MOP Measures of Performance MOS Measures of Suitability NESHAP National Emission Standards for Hazardous Air Pollutants NFPA National Fire Protection Agency OSHA Occupational Safety and Health Administration PM Prioritization Matrix QFD Quality Function Deployment SEI Software Engineering Institute SEMP Systems Engineering Management Plan SEP Systems Engineering Process SE Systems Engineering SME Subject-Matter Expert TCM Technology Compatibility Matrix TIM Technology Impact Matrix V&V Verification and Validation WBS Work Breakdown Structure WRS Wire Routing System
  • 7. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   7   ~ 1 SEMP  /  Project  Overview   1.1 Need  Statement     The goal of this project is to provide a proof of concept technology demonstration of a system for the accurate and repeatable routing of wire in 3D space, during wire harness manufacturing. Current methods of wire routing rely on antiquated techniques that require manufacturers to depend heavily on their fabricator’s attention to detail and personal motivation to produce high-quality products. Manual wire routing is prone to defects, inconsistencies, and unpredictable spans from initiation to completion. These elements add fabrication cost by increasing difficulty when planning work, forecasting material usage, and predicting time to completion. It is approximated that first pass quality defects increase harness costs by 6-12%A. The cost of poor initial quality is then magnified when lost time is factored into the price of wire harness fabrication. Therefore, harness manufacturers require a repeatable, accurate, and affordable system for routing wire during wire harnesses fabrication. Figure 1.1- Wire Harness Image found at www.quickwireharness.com/ Figure 1.2 - Form Board Image found at www.supremecable.com/ The Wire Routing System (WRS) will meet these industry needs through the use of automation, which will reduce touch labor hours and routing error. Precision mechanics further improve accuracy and repeatability. The use of automation for wire routing is unprecedented; it will require acute attention to our customers’ priorities throughout the entire systems engineering lifecycle. Aerospace and automotive harnesses manufacturers are the intended customers for the WRS. Utilizing the priorities of our customer, this document will ensure the value of repeatability, accuracy, ease of use, increased reliability, and the use of existing technologies is emphasized throughout the decision making process.
  • 8. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   8   ~ Development of an unprecedented system leaves this project vulnerable to increased levels of risk in the form of unknown- unknowns and scope creep. In an effort to mitigate this, several key assumptions were established from the inception of the WRS. The WRS concept demonstrator will: • Route a single wire at a time • Cut wire to designed length • Keep the final product in designed configuration until user is ready for product removal The wire harenss fabrication process was mapped to illustrate the scope of the WRS and maintain project focus in. See Figure 1.3, highlighted in green is the element of wire harness fabrication that is the focus of this effort. Planned future development will incrementaly expand the capabilities of the WRS and will incorporate other elements of the fabrication process; this is discussed further in the verification and validation section of this document. Figure 1.3 Wire Harness Fabrication Process
  • 9. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   9   ~ Figure 1.4 Wire Routing System Model The next steps in the team’s process involved the use of well-defined customer values, narrow scope, and a disciplined systems engineering approach to develop and evaluate various technologies in an effort to meet the customer needs. Based on our thorough analysis, we recommend the WRS be internally funded for further development. The WRS will quickly provide higher quality harnesses, with superior consistency than the current solutions. The WRS is a competitive advantage that positions us to earn new lines of business. 1.2 Project  Structure   To be developed during ASE 6004 2 Business  Case   To be developed during ASE 6004
  • 10. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 0   ~ 3 Requirements  Development  Process   Customer requirements were developed to define what the system should provide as well as define any system constraints. Well-written and thorough requirements have been critical to the success of the WRS because they ensure key customer needs are fulfilled. In  order  to  begin  the  process  of  defining  requirements  for  the  WRS,  the  customers  and   multiple  stakeholders  were  consulted  to  help  identify  the  essential  needs  that  the  system   should  fulfill.    The  customers  and  stakeholders  solicited  during  this  process  are  listed   below:     The target customers of the WRS will be wire harness manufacturers in both the automotive and aviation industries. All other groups listed above are stakeholders of the WRS and are important because they impose requirements on the system. For example, wire manufactures produce wire of a certain size and type which means the WRS must be compatible with wire provided. 3.1 Customer  Requirements   Generating requirements for an innovative product is a difficult process because there is not a clear understanding of the end product when the process begins. For this reason, the integrated development team (IDT) utilized brainstorming sessions and created use cases to help generate requirements. These two strategies will be discussed in further detail within this section. Brainstorming sessions with the customers and stakeholder were a great way to identify requirements for the system. The result was a large number of requirements, which served to address the wide variety of needs and constraints on the WRS. Brainstorming also resulted in a rough understanding of the system functionality. Based upon the results, the system should receive inputs from a variety of operators, perform its intended function and then output a wire, which is routed into a specific design. The rough understanding of the WRS functionality gained from the brainstorming sessions allowed the IDT to then create a use case diagram. This use case diagram can be seen in Figure 3.1 below. § Wire  Harness  Manufacturers   § Wire  Manufacturers   § Sustainment  Personnel   § Wire  Routing  Technicians   § Harness  Designers   § Quality  Control   § Wire  Harness  End  Users   § Regulatory  Agencies  
  • 11. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 1   ~   Figure 3.1  WRS  use  case  diagram The use case diagram of the WRS helped to identify requirements that were not generated during the brainstorming sessions. Note that WRS operators have been broken up into operators of individual actions. This was done to provide more insight into the individual interactions between the actors and the WRS. Identifying interactions and developing use case scenarios for them helped flush out additional requirements. Figure 3.2 provides an example of one use case scenario as well as the customer requirements that were derived from it. Figure 3.2 Use case for route wire The use case scenario presented a pre-condition where the WRS has a harness design loaded and the correct wire available to it. The basic flow section illustrates the actions taken by the operator and the WRS response to those actions. As an example of how use cases helped in generating customer requirements, Step 3 states that the WRS terminates (cuts) the wire at the Use  Case  Name 2.2  Navigate  Wire  in  3D  Space Use  Case  Description Wire  Routing  System  (WRS)  Routes  wire  based  upon  the  3  dimensional   design  provided  to  it Actor System  Command  Operator Pre-­‐conditions WRS  has  successfully  received  the  desired  wire  routing  design  and  wire   and  is  prepared  to  execute  wire  route  design Post-­‐conditions Wire  is  routed  along  the  desired  3  dimensional  route  and  constrained  in   place Misuse  Scenarios a.    Wire  feed  runs  out  of  wire b.    Wire  is  not  constrained  properly  and  falls  out  of  configuration Basic  Flow 1.    Operator  commands  the  WRS  to  begin  routing  operation 2a.    WRS  converts  design  path  format  into  mechanical  motion 2b.    WRS  feeds/lays/guides/prints  wire  along  the  design  path   2c.    WRS  constrains  the  wire  along  the  design  path  configuration  as              the  wire  is  put  in  place 3.    WRS  system  terminates  wire  at  the  end  of  the  wire  route  path 4.    WRS  communicates  to  Operator  that  the  wire  route  is  complete
  • 12. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 2   ~ end of the wire route path. This particular step indicated the need for a requirement on the WRS to limit the wire that exists outside of the routed envelope. In addition to the use cases in Figure 3.2, four (4) more use cases were developed for the following WRS-Operator interactions: • Receive  Wire  Path  Design   • Receive  Wire   • Accommodate  Removal  of  Wire   • Receive  Input   The use cases can be seen in Table 9-1 in Appendix I along with their respective misuse cases. A large number of customer requirements resulted from the use case scenarios and brainstorming sessions. To help organize and consolidate the requirements, the team utilized two key analysis tools; an affinity diagram and a tree diagram. The affinity diagram served to group the large amount of scattered requirements. This grouping is shown in Appendix I, Figure 9.1. By doing this, the team was able to identify requirements that were similar and could be consolidated. The full list of customer requirements can be seen in Appendix I, Table 9-2. Once the customer requirements were grouped and consolidated, they were organized by function and structured into a tree diagram. The WRS tree diagram can be seen in Appendix I, Figure 9.2. This began to paint a picture of how the system should be structured. It also identified gaps that the customer requirements didn’t address. The next step was to derive requirements to fill the gaps. 3.2 Derived  Requirements   Derived requirements are not explicitly stated in the set of customer requirements, yet are necessary to satisfy one or more of them. The tree diagram made it clear which customer requirements needed to be elaborated on. Figure 3.3 below shows several examples of requirements that were derived from the list of customer requirements  
  • 13. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 3   ~   Figure 3.3  Derived  Requirements  traceability  back  to  Customer  Require   The full list of derived requirements and their traceability back to the customer requirements can be seen in Appendix I, Table 9-3.   3.3 Requirements  Analysis  and  Prioritization   Once all of the customer and derived requirements were established and traceable, the team segregated the high level customer requirements and prioritized them based on customer importance. This was accomplished using an evaluation criteria matrix and a requirements prioritization matrix. First, the customer needs were scored against one another in the evaluation criteria matrix to determine the correct weighting associated with each one with respect to the others. This table can be seen in Appendix II, Table 9-4. Next, the high level customer requirements were ranked against one another based upon how vital they were to each weighted customer need. This process helped to identify the customers’ highest priority requirements and their respective derived requirements. The requirements priority matrix can also be seen in Appendix II, Table 9-5. The requirements development process helped to achieve a solid understanding of all the requirements and their priorities, which set the stage for the functional architecture development.    
  • 14. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 4   ~ 4 System  Architectures   4.1 Functional  Analysis     4.1.1 Functional  Architecture  Description     Based on the customer and derived requirements we developed a functional decomposition tree depicted in Figure 9.2 in Appendix I . The major system functions were identified, broken down and in some cases eliminated where necessary to remain within the project scope. This not only helped to identify testable conditions but also to derive further requirements. As the team broke down each function we began to establish the limits and boundaries of the WRS. Traceability of each function back to the original WRS customer requirements can be seen in Appendix IV Table 9-10. The tier 1 functions of our decomposition were Utility, Operation and Sustainment. Of these, the Operation decomposition led to most of the architectural features, while the Utility and Sustainment sub-functions greatly assisted in understanding the boundaries. The WRS functional architecture diagram is the baseline description of the WRS functionality and can be seen in the Hatley–Pirbhai model, Appendix III, Figure 9.4. From this functional decomposition we considered the sequence of the systems primary functions and how they relate to one another on many levels. The team decided to focus on the five key functions that drive the unique capability of this system. • 2.1.1 Receive Wire Path Design • 2.1.2 Deploy Wire • 2.2 Route Wire • 2.3.2 Accommodate Removal of Wire • 2.1 Receive Input This led to the development of a Hybrid Communication-Sequence model to address the flow of data and material throughout our system, see Section 6, Figure 6.1. The team also created a system boundary model to illustrate critical internal subsystem boundaries and how the WRS relates to external systems. 4.2 Concept  Exploration     Basic requirements of the system were established using industry need, as identified by experts. Varying levels of complexity were brainstormed. An interrelationship digraph was used to determine the sensitivity of early system requirements, see appendix III, Figure 9.3. User
  • 15. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 5   ~ interaction, routing wire to design specification, and maintainable were shown to be the most sensitive. It indicated that the preferred alternatives are focused on satisfying the most sensitive requirements. This focus will ensure robustness of the WRS design and reinforces the rational of the design architecture choices made by the team.         The IDT used pair-wise comparisons to prioritize the customer requirements and used these prioritized requirements to evaluate technology solutions identified during the technology market survey (TMS) based on their ability to fulfill the prioritized customer values from the technology impact matrix (TIM). A technology compatibility matrix (TCM) was then utilized to eliminate configurations that would not allow for full system functionality. The remaining options were organized into four (4) physical architecture alternatives. Each alternative was ranked against one another with respect to the five (5) prioritized customer values using the analytical hierarchal process. The analysis revealed that two (2) of the alternatives would be best suited to fulfill the customer need. Figure 4.1, Ranked Architecture Alternatives With only a 1.79% discrepancy between these alternatives, the IDT decided that further evaluation is needed to distinguish the two (2) options and will be performed during a later iteration of the systems engineering process. Figure 4.1 Ranked Architecture Alternatives 4.3 Architecture  &  Design  Specifications   4.3.1 Technology  Market  Survey     The WRS architectural design began with exhaustive technological research on five (5) key functionalities, outlined above in the functional architecture description, Section 4.1.1. The technology exploration illustrates information from a breadth of resources. These requirements took precedence in the analysis because they represent the underpinnings of development and will be integral in eventual system performance. The five (5) measures of effectiveness (MOE), which were refined by the integrated design team (IDT) served as the set of evaluation criterion in order to determine MOE relative importance amongst one another. The following is a
  • 16. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 6   ~ summary of the evaluation criteria matrix Appendix II, Table 9-4 and depicts the final % relative importance of each respective MOE. -­‐ Accuracy/Repeatability = 31% -­‐ Simplified User Operation = 10% -­‐ Increased Reliability = 20% -­‐ Lower Operating Cost = 28% -­‐ Use of Existing Technology = 11% Implementation of a TIM for each of the five (5) key functionalities provided a quantified analysis on technology options and their ability to meet each MOE. The next table displays the 1st and 2nd place technology options that arose from each TIM study. Table 4-1 First and second place technology options Technology  Option     WRS  Function   1st  Place     2nd  Place   Ref  2.1  –  Receive   Input       Form  Based  (29%)     WIMP/GUI  (27%)   Ref  2.1.1  –  Receive   Wire  Path  Design     Universal  Serial  Bus  (38%)   Wired  Network  (36%)   Ref  2.1.2  –  Receive   Wire     Gear  Wheel  Straightener   (31%)   Conveyorless  (28%)   Ref  2.2  –  Route   Wire     Linear  Ball  Slide  (46%)   Belt  Driven  (40%)   Ref  2.3.2  –   Accommodate  Removal   of  Wire     Mechatronics  (71%)   Operator  Based  Modular   Equipment  (29%)   This data analysis shows a major distinction (highlighted in red) between the ‘mechatronics’ and ‘operator based modular equipment’ characteristics—with ‘mechatronics’ yielding a 42% more impact to meet the WRS functional needs. This variation occurred for two (2) reasons: 1) The 9:3 ratio ‘mechatronics’ had against ‘operator based modular equipment’ for the MOE of accuracy/repeatability. 2) The 9:1 ratio ‘mechatronics’ had against ‘operator based modular equipment’ for the MOE of lower operating cost. On the other hand, the four (4) other WRS functions that were analyzed with a TIM showed a relatively low % discrepancy among technology options—all between 2-6%. Further iterations of trade studies will be performed in the future to compare technology options with more specificity. For example, there are various mechatronic and robotic technology designs available on the market that could possibly fit the WRS needs—so discriminating against them with
  • 17. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 7   ~ another TIM study will continue through Phase 1 of the test plan, Section 5, until PDR. An exact replica of each TIM study can be referenced in Appendix V, Table 9-11. Additional market survey analyses on three (3) low-impact WRS functions can be examined in Appendix V, Table 9-12. It should be noted, however, that these are not TIM studies, but do help break down the following WRS functions: -­‐ Ref. 1.1 Power Supply -­‐ Ref. 1.2.2 Remove Exhaust/Particulate -­‐ Ref. 2.1.1.1 Translate Design to Route 4.3.2 Physical  Architecture   Compatibility amongst technologies was the next analysis performed to down-scale physical architecture options using a TCM, Table 4-2 below. This technique discriminated amongst WRS technology options; those that would not be able to perform, or integrate, with one another. Table 4-2 Technology Compatibility Matrix 1  =  Incompattable Form  Based Capacitive  Touch  HMI Command  Line WIMP/GUI Wired  Network USB  2.0/3.0 Cloud  Based Gear  Wheel   Straightener Bearing  Wheel   Straightener Conveyorless Crank  Wheel Belt  Driven Linear  Ball  Slide Manual  Peg  Board Operator  Based   Modular  Equipment Mechatronics Ref.  2.1.2  Receive  Wire Ref.  2.3.2   Accommodate   Removal  of   Wire Ref.2.2  Route   Wire Ref.  2.1  Receive  Input Ref.  2.1.1  Receive   Wire  Path  Design Form  Based 0 1 1 1 1 1 Capacitive  Touch   HMI 0 1 1 1 1 Command  Line 0 1 1 1 WIMP/GUI 0 1 1 Wired  Network 0 1 1 1 1 USB  2.0/3.0 0 1 1 1 Cloud  Based 0 1 1 Gear  Wheel   Straightener 0 1 1 1 1 1 Bearing  wheel   straightener 0 1 1 1 1 Conveyorless 0 1 1 Crank  Wheel 0 1 1 1 Belt  Driven 0 1 1 1 Linear  Ball  Slide 0 1 1 Manual  Peg  Board 0 1 Operator  Based   Modular   0 1 Mechatronics 0 Ref.2.2  Route  Wire Ref.  2.3.2   Accommodate   Removal  of  Wire Ref.  2.1  Receive   Input Ref.  2.1.1  Receive   Wire  Path  Design Ref.  2.1.2  Receive   Wire
  • 18. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 8   ~ Results of this analysis poised the IDT assigned to the WRS to arrive at four (4) varying physical design architectures shown below in Table 4-3. Table 4-3 Physical Architecture Alternatives These four (4) architecture alternatives include: -­‐ High TRL Interface -­‐ Advanced Interface -­‐ Easy to Use -­‐ Bare Bones Basic Two (2) of the architecture alternatives only differ in the WRS function Ref. 2.1 Receive Input: the ‘High TRL Interface’ and ‘Advanced Interface’ alternatives, while the others have a greater deal of variation among technology options. These architecture alternatives will include a list of interface control documents, which will be adequately defined and documented for PDR in the future. 4.3.3 Architecture  Documentation   To be developed during ASE 6004 4.3.4 Architecture  Quality  Attributes   To be developed during ASE 6004 5 System  Verification  and  Validation     We have been and will be preforming review and test sequences throughout our system’s development. The team intends to use a mix of Informal, Static and Dynamic verification and validation methods. A compliance matrix is included in Appendix IV, Table 9-9 to ensure that requirements set by regulatory bodies are met. The team has established a series of preliminary design review (PDR) entrance and exit criteria. Similar reviews will be performed to ensure that the engineering team does not lose sight of the customer need. Critical stages of development will include multiple reviews. Each of WRS  Function High  TRL  Interface Easy  to  Use Bare  Bones  Basic Advanced  Interface Ref.  2.1  Receive  Input Form  Based WIMP/GUI Form  Based WIMP/GUI Ref.  2.1.1  Receive   Wire  Path  Design Wired  Network USB  2.0/3.0 USB  2.0/3.0 Wired  Network Ref.  2.1.2  Receive   Wire Gear  Wheel  Straightener Bearing  Wheel  Straightener Conveyorless Gear  Wheel   Straightener Ref.  2.2  Route  Wire Linear  Ball  Slide   Belt  Driven Belt  Driven Linear  Ball  Slide Ref.  2.3.2   Accommodate   Removal  of  Wire Mechatronics Mechatronics Operator  Based   Modular  Equipment Mechatronics Physical  Architecture  Alternatives
  • 19. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   1 9   ~ these reviews will compare the stated goals of a stage and the results; all criteria must be satisfied before moving on to the next stage. A similar review will be performed at the onset of each new stage to properly define and communicate the goals to the team. These verification activities will take place throughout the research and development of the WRS, however, during procurement and integration a much more formal process will be utilized. For these critical stages a four phase validation plan has been developed and can be found in Appendix IV Tables 9-6 and 9-7. The 4 phases are as follows: Phase  1   Phase  2   Phase  3   Phase  4   Individual  Component   Testing/  Middleware  AoA   Subsystem   Integrations   System  Level   Integrations   Prototype  Testing  incl.   Operation  and  Quality   Phase 1 will address the entry and exit to the component procurement stage of the project. An evaluation of the various component options that resulted from our technology market study will be used to develop further AoAs of the identified technology suites. Each suite will be defined by the communication protocols and signals utilized; a technology impact matrix (TIM) will ensure that no incompatibilities are built in to the WRS. Phase 2 will mirror phase 1, incorporating mechanical and structural considerations. The results of this stage will derive further requirements for the selection of the WRS operating system. Phase 3 will run through a similar process as the previous two phases, this time for the assembled subsystems. Testing of the software operating system that best fits the decisions made in Phases 1 & 2 will occur as well. While each phase will be broken up into various subsections for continuity, those in Phase 4 are the most critical and must be considered very early in development for the project’s success. Once cleared to proceed to Phase 4 the team will begin integrating those subsystems that resulted from Phases 2 & 3. The first stage (Appendix IV, Table 9-6, Phase 4.1) of Phase 4 will review the mechanical and structural interfaces. Upon acceptance of Review Gate 4.2(Appendix IV, Table 9-7) operational testing (Appendix IV, Table 9-6, Phase 4.2) will begin to confirm that the software and control systems react as expected during both normal operation as well as fault and failure scenarios. Once operational testing has been successfully completed, quality testing will begin. This stage (Appendix IV, Table 9-6, Phase 4.3) will address the ability of the WRS to produce a consistent product within the required specifications and confirm the systems durability. Phase 4 testing will be deemed successful once a technology demonstration has been performed and the customer is satisfied with the results. However, in the event that the system does not perform as
  • 20. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 0   ~ expected the team will continue to the Rework (Appendix IV, Table 9-6, Phase 4.4) and Retest (Appendix IV, Table 9-6, Phase 4.5) stages. It is very important to note that review gates scheduled during this plan will elicit and allow the team to act upon stakeholder feedback relevant to the progress and direction of the WRS. A fifth phase will be implemented upon customer acceptance of the proof of concept system. Phase 5 will include production validation, hardware improvements, additions and software upgrades while verifying that the customer needs continue to drive development. 6 Design  Model     The WRS has a complex set of communication requirements between components, which requires a rigid set of boundary definitions. The following hybrid communication-sequence diagram demonstrates how data traverses the WRS from user execution through the WRS and to the delivery system. The WRS boundary diagram shows communications between hardware-software-hardware. Each item that has a shared border in the graph is illustrating that there are communications between them. Items within a red box are out of scope for our project, but still have communications between them. This communication must be further developed for each incremental upgrade in system capability.
  • 21. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 1   ~ Figure 6.1 Hybrid Communication-Sequence Diagram Feeds wire on demand Attributes Wire De-reeler Routes physical wire in 3D space One routes a single wire at a time Motors/PLCs Middleware Transfers data to low level middleware Hard/software WRS UX Feeds wire on demand Holder of final product Wire Delivery Request wire from external system Send sequence to low level hardware Move final product to delivery state Inform user that product is final
  • 22. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 2   ~ Figure 6.2 WRS boundary diagram 7 Project  Summary   To be developed during ASE 6004 7.1 Work  Breakdown  Structure   The WBS for the entire system development program is shown in Appendix V, Figure 9.5. Each separate root (W<single digit #>) is a tier 1 level in the breakdown. Delineating from those are the next work breakdown tiers and they reflect other major elements of the WRS program in its entirety, from assembly and test to sustainment.   Project  Management  WBS   The WBS W1 refers to all elements related to the WRS program development, including vendor oversight, procurement management, and facility related issues. User/Software UX Version 1 «precondition» pre «postcondition» post Wire De-reeler «precondition» Wire present «postcondition» WRS requesting wire, or FIN signal Delivery system «precondition» Wire harness present «postcondition» Remove final product 3D CAD codec Version 1 Hardware Version 1 WRS 3D encoding Version 1 Middleware Version 1 High2Low translator Version 1 Sequencing Version 1 PLC Version 1 Adadapters/ Connectors Version 1 Structure Version 1 Out of bounds Software Hardware Enclosure
  • 23. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 3   ~   Systems  Engineering  WBS   The WBS W2 involves the development of technical expertise, SEMP and the ConOps. Understanding and updating of related technical documentation falls upon these R&D and product development personnel.   Interface  Systems  WBS   The WBS W3 falls under the purview of the SME in relation to interface systems technology. PDR on this issue will come through his or her oversight, and will be founded upon appropriate research and documentation.   Control  System  WBS   The WBS W4 provides a breakdown of work associated with WRS control system development. This includes process control, automation, and regulation of electro-mechanical systems.   Mechanical  System  WBS     The WBS W5 for the Mechanical System is the most extensive aspect of the WRS. This work breakdown involves hardware design and fabrication, component integration, along with a large amount of V&V activities.   Management  Reserve  WBS   In order to better accommodate best practices, an allotted amount of reserve funds will be distributed amongst three (3) sectors of WRS development: quality risk, cost risk, & schedule risk. Early acknowledgement that there is a certain amount of risk involved in full scale development provide a greater probability of success.   Assembly  and  Test  WBS   The WBS W7 for Assembly and Test provides process quality management in regards to complete fabrication of validated devices. This will be supervised by the all W2.2 personnel including: electrical lead, mechanical lead, team lead, software lead, and drafter.   Sustainment  WBS   The WBS W8 heavily details the development of manuals and training. Maintenance schedules for the WRS will be discussed and developed, along with repair procedures for system components. It is the responsibility of the PM and the SE to lead this process to completion.
  • 24. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 4   ~ 7.2 Project  Plan   To be developed during ASE 6004 7.3 Risk  Management   To be developed during ASE 6004 8 Lifecycle  Management  Plan   To be developed during ASE 6004 8.1 Deployment  Plan   To be developed during ASE 6004 8.2 Support  Plan   To be developed during ASE 6004 8.3 Cost  Estimates     The cost estimates were derived by first identifying the top elements from our work breakdown schedule. This included: • Project Management • Systems Engineering • Interface Systems • Control System • Mechanical Systems • Assembly and Test • Management Reserve • Sustainment Second, using our determined deliverable life cycle methodology, we identified our tier one cost elements from the WBS, and the subordinate elements in relation to our project life cycle. The team labeled risks for each cost element, and the type of distribution patterned matched each element’s risk factors. Some factors that influenced risks to the project were, supply chain management, integration factors, scope, resource conflicts, changing customer requirements and political influences. Project Management: The project manager will be most crucial at the beginning of the project, but will still be integral throughout the entire life cycle. We used a lognormal distribution because the risks at the beginning are very high, but die slowly as the project reaches the end of life.
  • 25. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 5   ~ Systems Engineer: Like the project manager the systems engineer will be critical to the entire project life cycle, but will have slightly less risk in the beginning, and the highest amount of risk will be centered around the integration, validation and verification phase because of this we chose a Gaussian distribution. Interface Systems: The interface system has its highest amount of risk around beginning to middle of the whole project life. The risk for this element comes from unit testing each software/hardware component, and integration with the rest of the system. We believe that this risk pattern is best modeled with a Gaussian distribution. Control Systems: The control system development is the cost element that pertains to the translating of 3D cad file to a time-series plan for each mechatronic component to route a wire in 3D space. The risk for this cost element is Gaussian because it is needed for Mechanical Systems: The risks for the mechanical systems has the greatest amount of the risk due to the amount and variety of mechatronic components as well as the supply chain logistics to obtain the parts. The amount of risk best fit a triangular (Mean (a+b+c)/3; Variance (a^2+b^2+c^2 –ab-ac-bc)/18) distribution curve because this cost element changes significantly through each phase due to integration. Assembly and Test: The assembly and testing of all the component is a vital cost element for this project. Because we are using items with a higher technology readiness we won’t have as a high of a risk at any one phase of the project, but we will have a lognormal (Mean (e^µ+ σ^2)/2; Variance ((e^ σ^2) -1)(e^2*µ+ σ^2)) distribution curve that will slowly go to zero as the project finishes its full life cycle. Management Reserve: The management reserve fund is a fixed cost, and will provide the project with a set of monies for project issues that are unforeseen, or need extra resources to keep the project on time. Sustainment: Sustainment will cover development of maintenance and repair guides, as well as personnel to do the actual repairs/maintenance. This element will be later in the whole project life cycle, and should be have a lesser amount of risk because it is at the end of development. This is why we believe that the risk pattern for this is a normal distribution curve.   9 Appendices   9.1 Appendix  I  Requirements   Table 9-1 Use and misuse case scenarios based upon the use case diagram
  • 26. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 6   ~ Use  Case  Name 2.1.1  Receive  Wire  Path  Design Parent  Use  Case  Name 2.1.1  Receive  Wire  Path  Design Use  Case  Description Wire  Routing  System  (WRS)  receives  a  3  dimensional  wire  harness  design   from  operator Misuse  Case  ID 2.1.1a    Unrecognized  file  type  loaded Actor Route  Design  Operator Misuse  Case  Description WRS  does  not  recognize  the  wire  harness  design  file  format Pre-­‐conditions WRS  has  no  wire  harness  design  to  execute Actor Operator Pre-­‐conditions WRS  has  no  wire  harness  design  to  execute Basic  Flow 1.    Operator  activates  WRS 2.    Operator  makes  the  wire  harness  design  available  to  WRS 3.    Operator  utilizes  WRS  user  interface  system  to  select  correct  wire              harness  design 4.    WRS  does  not  recognize  file  type   5.    WRS  generates  error  message  displayed  through  user  interface 6.    WRS  prompts  Operator  to  re-­‐attempt  file  selection Post-­‐conditions WRS  has  identified  wire  harness  design  and  is  prepared  to  execute  it Post-­‐conditions WRS  has  communicated  file  type  error  and  awaits  new  file Misuse  Scenarios a.    Unrecognized  file  type  loaded Use  Case  Name 2.1.2  Receive  Wire   Parent  Use  Case  Name 2.1.2  Receive  Wire   Use  Case  Description Wire  Routing  System  (WRS)  receives  wire  from  the  Operator Misuse  Case  ID 2.1.2.a    Incorrect  wire  loaded Actor Wire  Provider  Operator     Misuse  Case  Description Operator  provides  the  wrong  size/type  wire Pre-­‐conditions WRS  has  identified  wire  type  and  size  needed  for  wire  harness  design;   Correct  wire  type  and  size  are  available   Actor Operator     Pre-­‐conditions WRS  has  identified  wire  type  and  size  needed  from  wire  harness  design;   Correct  wire  type  and  size  are  available   Basic  Flow 1.    WRS  communicates  to  the  operator  what  wire  type  is  need  for  the              design 2.    WRS  provides  step  by  step  instructions  showing  operator  how  to              load  wire 3.    Operator  follows  steps  presented  and  prepares  the  WRS  to              receive  the  wire 4.    Operator  makes  the  incorrect  wire  available  to  the  WRS  system 5.    WRS  recognizes  incorrect  wire  loaded   Post-­‐conditions WRS  has  successfully  received  wire  and  is  prepared  to  execute  desired   wire  route  design Post-­‐conditions WRS  has  communicated  wire  size/type  error  and  awaits  correct  wire   Misuse  Scenarios a.    Incorrect  wire  loaded Use  Case  Name 2.2  Navigate  Wire  in  3D  Space Parent  Use  Case  Name 2.2  Route  Wire Use  Case  Description Wire  Routing  System  (WRS)  Routes  wire  based  upon  the  3  dimensional   design  provided  to  it Misuse  Case  ID 2.2.a  Wire  feed  runs  out  of  wire Actor System  Command  Operator Misuse  Case  Description Operator  did  not  load  enough  wire  to  complete  route Pre-­‐conditions WRS  has  successfully  received  the  desired  wire  routing  design  and  wire   and  is  prepared  to  execute  wire  route  design Actor WRS,  Operator Pre-­‐conditions WRS  has  successfully  received  the  desired  wire  routing  design  and  wire   and  is  prepared  to  execute  wire  route  design Basic  Flow 1.    WRS  communicates  to  the  operator  that  the  WRS  is  prepared  to              execute  wire  route  design 2.    Operator  commands  the  WRS  to  begin  routing  operation 3.    WRS  compares  wire  route  design  to  quantity  of  wire  available  in  wire            feed 5.    WRS  generates  error  message  stating  insufficient  quantity  of  wire   Post-­‐conditions Wire  is  routed  along  the  desired  3  dimensional  route  and  constrained  in   place Post-­‐conditions WRS  has  communicated  wire  quantity  error  and  awaits  receipt  of  more   wire   Misuse  Scenarios a.    Wire  feed  runs  out  of  wire b.    Wire  is  not  constrained  properly  and  falls  out  of  configuration Use  Case  Name 2.3.2    Accommodate  Removal  of  Wire Parent  Use  Case  Name 2.3.2    Accommodate  Removal  of  Wire Use  Case  Description Wire  Routing  System  (WRS)  enables  the  removal  of  a  successfully  routed   wire  which  has  been  constrained  in  place Misuse  Case  ID 2.3.2.a  Improper  Wire  Handling Actor WRS,  Operator Misuse  Case  Description 1.    Wire  is  not  released  properly  and  falls  out  of  configuration Pre-­‐conditions WRS  has  successfully  routed  and  constrained  wire  but  it  is  still  contained   within  the  system Actor WRS,  Operator Pre-­‐conditions WRS  has  successfully  routed  and  constrained  wire  but  it  is  still  contained   within  the  system Basic  Flow 1.    WRS  communicates  to  the  operator  what  wire  type/size  is  need  for            the  desired  design 2.      WRS  provides  step  by  step  instructions  showing  operator  how  to              load  wire 3.    Operator  does  not  correctly  follow  removal  steps  and  wire  falls  out  of              configuration  during  removal 4.      WRS  generates  error  message  stating  routed  wire  is  out  of                configuration 5a.  Operator  restores  wire  to  correct  configuration  and  proceeds  with                  removal 5b.  Operator  removes  wire  with  incorrect  configuration  and  resorts  back                  to  Function  2.2.  Route  Wire Post-­‐conditions Wire  is  removed  from  WRS  in  the  desired  route  configuration Post-­‐conditions WRS  has  communicated  wire  configuration  error  and  awaits    next  step   from  Operator Misuse  Scenarios a.    Improper  Wire  Handling Basic  Flow 1.    Operator  activates  WRS 2.    Operator  makes  the  wire  harness  design  available  to  WRS 3.    Operator  utilizes  WRS  user  interface  system  to  select  correct  wire              harness  design 4.    WRS  System  recognizes  file  format  of  wire  harness  design 5.    WRS  indicates  that  receipt  of  wire  harness  design  was  successful Basic  Flow 1.    Operator  commands  the  WRS  to  begin  routing  operation 2a.    WRS  converts  design  path  format  into  mechanical  motion 2b.    WRS  feeds/lays/guides/prints  wire  along  the  design  path   2c.    WRS  constrains  the  wire  along  the  design  path  configuration  as              the  wire  is  put  in  place 3.    WRS  system  terminates  wire  at  the  end  of  the  wire  route  path 4.    WRS  communicates  to  Operator  that  the  wire  route  is  complete Basic  Flow 1.    Operator  request  wire  type/size  for  harness  design 2.    WRS  communicates  to  the  operator  what  wire  type/size  is  need  for              the  desired  design 3.      WRS  provides  step  by  step  instructions  showing  operator  how  to              load  wire 4.    Operator  follows  steps  presented  and  prepares  the  WRS  to              receive  the  wire 5.    Operator  makes  the  wire  available  to  the  WRS  system 6.    WRS  system  receives  wire  and  indicates  to  user  that  the  wire  is              successfully  received 1.    WRS  communicates  to  the  operator  that  the  wire  routing  process              is  complete. 2.    Operator  indicates  to  the  WRS  the  desire  to  remove  wire  from              system 3.    WRS  ensures  wire  is  securely  constrained  in  configured  route 4.    WRS  maneuvers,  allowing  Operator  access  to  the  routed  wire   5.    WRS  releases  wire  constraints  as  necessary  to  allow  removal  of              wire  without  losing  route  configuration 6.    Operator  communicates  to  the  WRS  that  the  wire  is  successfully              removed  and  the  WRS  is  clear  of  personnel  or  obstruction 7.    WRS  system  maneuvers  back  to  operational  configuration Basic  Flow
  • 27. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 7   ~ Table 9-2 Complete list of WRS customer requirements Table 9-3 Complete list of WRS derived requirements Figure 9.1 Affinity diagram of customer requirements Use  Case  Name 2.1  Receive  Input Parent  Use  Case  Name 2.1  Receive  Input Use  Case  Description Wire  Routing  System  (WRS)  receives  input  from  operator Misuse  Case  ID 2.1.a  Workstation  Misuse Actor System  Command  Operator   Misuse  Case  Description Operator  wants  to  perform  an  operation  that  is  not  displayed Pre-­‐conditions WRS  is  in  a  state  of  standby  awaiting  input  from  Operator Actor Operator Pre-­‐conditions WRS  is  in  a  state  of  standby  awaiting  input  from  Operator Basic  Flow 1.    WRS  communicates  to  Operator  what  current  state  of  system  is 2.    WRS  presents  next  step  options  to  Operator 3.    Operator  determines  most  applicable  next  step  of  desired  outcome 4.    Operator  does  not  see  desired  option 5.    Operator  returns  to  "main  menu" 6.  Operator  navigates  to  desired  input. 7.    Operator  commands  WRS  to  perform  desired  next  operation 8.    WRS  received  input  and  is  ready  to  performs  command Post-­‐conditions WRS  has  successfully  received  desired  input  and  is  ready  to  perform   command Post-­‐conditions WRS  has  successfully  received  desired  input  and  is  ready  to  perform   command Misuse  Scenarios a.    Workstation  Misuse Basic  Flow 1.    WRS  communicates  to  Operator  what  current  state  of  system  is 2.    WRS  presents  next  step  options  to  Operator 3.    Operator  determines  most  applicable  next  step  of  desired  outcome 4.    Operator  commands  WRS  to  perform  desired  next  operation 5.    WRS  received  input  and  is  ready  to  performs  command Req. # Req. Origin Requirement Short Text Requirement Long Text CR1 D2.OPERATOR.BD.01 Manual  activation  and  deactivation Operator  shall  be  provided  means  to  activate  and  deactivate  the  WRS  manually CR2 D2.OPERATOR.BD.04.1 Means  to  remove  completed  product The  WRS  shall  provide  operator  means  to  remove  the  completed  product CR3 D2.OPERATOR.BD.02.1 Uploaded  wire  route  path Operator  shall  be  provided  means  to  upload  wire  route  path  data  into  the  WRS  software CR4 D2.OPERATOR.BD.02 User  Interface The  WRS  shall  provide  operator  a  graphical  user  interface CR5 D2.SYSTEM.TD.04 Visual  and  oral  queues The  WRS  shall  include  visual  and  oral  queues  to  guide  operation CR6 D2.SYSTEM.TD.11 Uses  CNC  routing  files The  WRS  shall  accept  CNC  routing  files CR7 D2.SYSTEM.TD.08 Maintainable The  WRS  shall  be  capable  of  receiving  maintenance CR8 D2.SYSTEM.TD.03 Routes  wire  in  3D  space The  WRS  shall  route  wire  in  three  dimensional  space CR9 D2.SYSTEM.TD.06 Auto  shutoff The  WRS  shall  include  an  automatic  shutoff CR10 D2.SYSTEM.TD.15 Provides  status  to  operator The  WRS  shall  provide  operational  status  to  operator CR11 D2.SYSTEM.TD.01 Provide  hazard  protection The  WRS  shall  protect  bystanders  from  hazards  presented  by  moving  parts CR12 D2.SYSTEM.TD.07 Modular   The  WRS  shall  be  modular  to  allow  for  future  expansion CR13 D2.WIRE.CV.07 Limit  wire  waste The  wire  that  exists  outside  the  routed  envelope  shall  be  limited  to  a  designated  length CR14 D2.WIRE.CV.03 Routes  wire  within  design  specifications The  WRS  shall  produce  routed  wire  that  meets  design  path  tolerance  specified  within  engineering  requirements CR15 D2.WIRE.CV.06 Wires  can  be  grouped The  routed  wire  shall  be  capable  of  being  grouped  together  with  other  wires  routed  along  the  same  path CR16 D2.UTILITY.KL.06 Electrically  grounded The  WRS  shall  be  electrically  grounded  to  comply  with  national,  state,  and  local  regulations CR17 D2.UTILITY.KL.07 Surge  protection The  WRS  shall  incorporate  utility  surge  protection CR18 D2.LIFE.AS.05.1 Components  must  fit  through  doorways The  WRS  shall  disassemble  to  fit  through  NFPA  standard  openings CR19 D2.SUSTAINMENT.SM.01 Uses  commercial  software The  Wire  Routing  System  shall  use  existing  Commercial-­‐off-­‐the-­‐Shelf  (COTS)  software CR20 D2.SUSTAINMENT.SM.04 Calibratable The  WRS  shall  incorporate  calibration  as  required  to  maintain  engineering  specifications CR21 D2.UTILITY.KL.05 Manages  waste The  WRS  shall  manage  byproduct  waste CR22 D2.UTILITY.KL.01 Powered  by  local  utilities The  WRS  shall  be  powered  by  local  power  utilities WRS Customer Requirements Req. # Cust. Req. Trace Requirement Short Text Requirement Long Text DR22.1 CR22 Convert  Power Power  infusion  to  system  shall  be  distributed  within  standard  safety  parameters  of  the  power  source. DR22.2 CR22 Distribute  Power The  WRS  shall  provide  Individual  electrical  components  with  the  appropriate  power DR22.3 CR22 Operational  Conditions The  WRS  shall  provide  operational  environment  for  components DR21.1 CR21 Provide  Ventilation WRS  shall  have  a  sub-­‐system  exhaust  ventilation  to  meet  quality  standards  dictated  by  EPA. DR14.1 CR6 Translate  Design  to  Route The  WRS  shall  read  CNC  file  types  and  convert  into  mechanical  motion  to  implement    wire  routing  designs DR.8.1 CR4, CR14 Receive  Wire The  WRS  shall  receive  wire  based  upon  routed  wire  specifications DR8.2 CR8 Support  Routed  Wire Routed  wire  shall  remain  in  routed  configuration  within  design  tolerances  until  further  processing DR8.3 CR14, CR15 Deploy  Wire The  WRS  shall  deploy  wire  along  design  path  during  mechanical  motion DR7.1 CR7 Receive  Lubricant The  WRS  components  shall  be  capable  to  receive  lubricant DR19.1 CR7, CR19 Programmable  Software the  WRS  software  package  shall  accept  prescribed  updates DR7.2 CR7, CR12 Replaceable  Interchangeable  Parts The  WRS  shall  utilize  commercially  available  hardware  to  prevent  obsolescence DR12.1 CR12, CR18 Mechanically  &  Electrically  Separable The  WRS  shall  incorporate  reusable  connections  between  components DR21.2 CR21 Utilize  Recyclable  Material The  WRS  shall  adhere  to  environmental  sustainment  regulations WRS Derived Requirements
  • 28. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 8   ~
  • 29. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   2 9   ~ Figure 9.2 Functional Tree Diagram 9.2 Appendix  II  Requirements  Analysis   Table 9-4 WRS evaluation criteria matrix Wire Routing System 1 Utility 2 Operation 3 Sustainment 1.1 Receive Power 1.1.1 Convert Power 1.1.2 Surge Protect 1.1.3 Ground Power 1.1.4 Distribute Power 1.2 Ventilate Components 1.2.1 Cool Electronics 1.2.2 Remove Exhaust/ Particulate 2.1 Receive Input 2.1.1 Receive Wire Path Design 2.1.1.1 Translate Design to Route 2.1.2 Receive Wire 2.1.3 Receive Start/ Stop 2.2 Route Wire 2.2.1 Navigate Wire in 3D Space 2.2.3 Support Routed Wire 2.2.2 Deploy Wire 2.2.1.1 Deliver Wire along path 2.2.1.2 Allow for Grouping 2.3 Produce Output 3.1 Maintainable Functionality 3.1.1 Capable of Receiving Service 3.1.2 Capable of Receiving Repairs 3.1.2.1 Replaceable Interchangeable Parts 3.1.1.1 Calibration Capable 3.1.1.2 Capable of Receiving Lubricant 3.1.1.3 Programmable Software 3.2 Transportable Components 3.2.1 Decomposable Modules 3.2.1.1 Mechanically & Electrically Separable 3.3 Environmentally Friendly 3.3.1 Utilize Recyclable Material 3.3.2 Use Reusable Parts 2.3.1 Communicate Messages 2.3.2 Accommodate Removal of Wire 2.3.3 Remove Debris/ Waste 2.1.3.1 Activate Device 2.1.3.2 Deactivate Device
  • 30. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 0   ~ Table 9-5 WRS requirements prioritization matrix Evaluation Criteria Options Increase Accuracy / Repeatability Simplify User Operation Increase Reliability Lower Operating Cost Use Existing Technology Total across rows % Grand total A. Powered by local utilities [20] 0.0128 0.0012 0.0237 0.0160 0.0062 0.0599 0.0627 B. Provide hazard protection [10] 0.0063 0.0038 0.0138 0.0184 0.0029 0.0451 0.0473 C. Provide routed wire to operator [2] 0.0165 0.0150 0.0033 0.0229 0.0051 0.0628 0.0658 D. System is Transportable [18] 0.0059 0.0044 0.0088 0.0031 0.0025 0.0247 0.0259 E. Maintainable components [7] 0.0465 0.0078 0.0442 0.0117 0.0063 0.1166 0.1221 F. Receive operator inputs[1] 0.0065 0.0072 0.0135 0.0083 0.0041 0.0397 0.0416 G. Receive wire route path from operator [3] 0.0349 0.0177 0.0079 0.0265 0.0081 0.0951 0.0996 H. User Interface [4] 0.0167 0.0221 0.0262 0.0407 0.0155 0.1211 0.1269 I. Provides status to operator [9] 0.0159 0.0152 0.0279 0.0158 0.0039 0.0787 0.0824 J. Uses commercial software [16] 0.0076 0.0027 0.0100 0.0122 0.0266 0.0592 0.0620 K. Route wire within design specifications [22] 0.0930 0.0012 0.0118 0.0049 0.0041 0.1150 0.1205 L. Wires can be grouped [13] 0.0408 0.0091 0.0026 0.0279 0.0018 0.0822 0.0861 M. Manages waste [19] 0.0074 0.0073 0.0027 0.0279 0.0093 0.0546 0.0572 Column Total 0.3109 0.1146 0.1964 0.2364 0.0965 0.9548 1.0000
  • 31. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 1   ~ 9.3 Appendix  III  Architecture   Figure 9.3 Interrelationship Digraph  
  • 32. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 2   ~ Figure 9.4 Hatley–Pirbhai modeling
  • 33. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 3   ~ 9.4 Appendix  IV  V  &  V   Table 9-6 Four (4) Phase Test Plan Phase Description Strategy/Approach Scope 1 Individual Component Testing/ Firmware AoA Research & Sample, Compare configurations of hardware components of various programming languages Requirements Design Development(RDD) Behavior model, Default Behavior, Code hours Estimation Determine the capabilities limitations of available options for Phase 2 & 3 selections 2 Subsystem Level Hardware integration testing Build subsystems based on the Phase 1 recommendations Interoperability of firm/middleware and PLCs, Ensure that the pieces work well in the suggested arrangement and determine alternatives where necessary, Firmware teardown 3 Subsystem Level Software integration testing Define boundaries and error states Interoperability of firm/middleware and software, RDD Test In Process Review(does the code match the expected behavior model, bug fix, Rigorous code walkthrough, Ensure that the programs work well in the suggested arrangement and determine alternatives where necessary 4 Prototype Test Final Validation/ Rework as needed per customer input Integrate Phase 2&3 subsystems and Identify Deficiencies/The pieces fit together-do they work together 4.1 Mechanical Interface/ Interference Tests Interface Analysis & Testing, Structural Testing Verify mechanical interfaces do not become interferences 4.2 Operational Testing Fault Failure Insertion, Functional (black box) testing when an error is encountered/produced does the system react as intended unforeseen errors/reactions? 4.3 Quality testing Top-Down Testing, Fatigue Testing Real world simulations, Routed wire tolerance and repetition 4.4 Rework Bottom-Up Testing Apply Necessary Corrections 4.5 Retest Restart Phase 4 5 Future Integrations Add on features & software updates Beyond the 2yr scope of Baseline Model development
  • 34. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 4   ~ Table 9-7 Review Gate Table PHASE ENTRY GATE SCOPE PHASE EXIT GATE SCOPE Review Gate 1.1 Determine if we are ready to begin component procurement and testing Review Gate 1.2 Determine that previous phase was successful and completed to allow project to move forward, STAKEHOLDER INPUT REQUIRED Review Gate 2.1 Determine if we are ready to begin component integration and testing Review Gate 2.2 Determine that previous phase was successful and completed to allow project to move forward Review Gate 3.1 Determine if we are ready to begin system integration and testing Review Gate 3.2 Determine that previous phase was successful and completed to allow project to move forward, STAKEHOLDER INPUT REQUIRED Review Gate 4.1 Determine if we are ready to begin system operational testing Review Gate 4.2 Determine that mechanical subsystems are appropriate Review Gate 4.3 Determine that mechanical subsystems are properly limited by operatin system Review Gate 4.4 Determine that software controls are properly limited, hardware properly monitored Review Gate 4.5 Determine complete or repeat, STAKEHOLDER INPUT REQUIRED Review Gate 4.6 Determine the scope and objective of necessary rework Review Gate 4.7 Determine success of rework Review Gate 4.1a Refer to Review Gate 4.1
  • 35. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 5   ~ Table 9-8 Validation Matrix TRACE  ID   TEST  PLAN       Decomposed   Function   Customer   Requirement   Derived   Requirement     Phase  1     Phase  2     Phase  3     Phase  4   1       ✓ ✓ 1.1       ✓ ✓ 1.1.1   CR22   DR22.1   ✓ 1.1.2   CR17,  CR9,  CR11     ✓ 1.1.3   CR16,  CR11     ✓ 1.1.4   CR22   DR22.2   ✓ ✓ ✓ 1.2       ✓ ✓ 1.2.1   CR22   DR22.3   ✓ ✓ ✓ 1.2.2   CR21   DR21.1   ✓ ✓ 2       ✓ 2.1       ✓ ✓ 2.1.1   CR3     ✓ 2.1.1.1   CR6   DR14.1   ✓ 2.1.2   CR4,  CR24   DR.8.1   ✓ ✓ ✓ 2.1.3   CR1     ✓ ✓ 2.1.3.1   CR1     ✓ 2.1.3.2   CR1,  CR9     ✓ 2.2       ✓ ✓ 2.2.13   CR8,  CR14     ✓ ✓ ✓ 2.2.1.1   CR15,  CR14     ✓ 2.2.1.2   CR15     ✓ 2.2.2   CR8   DR8.2   ✓ ✓ 2.2.3   CR14,  CR15   DR8.3   ✓ ✓ 2.3       ✓ 2.3.1   CR4,  CR5,  CR10     ✓ 2.3.2   CR2     ✓ ✓ 2.3.3   CR21,  CR13     ✓ ✓ 3       ✓ 3.1       ✓ 3.1.1   CR7     ✓ 3.1.1.1   CR20,  CR7     ✓ ✓ 3.1.1.2   CR7   DR7.1   ✓ ✓ 3.1.1.3   CR7,  CR19   DR19.1   ✓ ✓ ✓ 3.1.2   CR7     ✓ ✓ 3.1.2.1   CR7,  CR12   DR7.2   ✓ ✓ 3.2       ✓ 3.2.1   CR12,  CR18     ✓ ✓ 3.2.1.1   CR12,  CR18   DR12.1   ✓ 3.3       ✓ 3.3.1   CR21   DR21.2   ✓ 3.3.2   CR21   DR21.3   ✓ ✓
  • 36. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 6   ~ Table 9-9 Compliance Matrix Requirement  Source   Category   Verification  Method   Verification  Status   (NV  =  not  verified,   V  =  verified)   Acceptance  Criteria   Customer  Requirement   Source   Functional   Identifier   Derived   Requirement   Identifier   Customer   Requirement   Identifier   NFPA  70B;  OSHA  29  CFR   1910.  269;  IEEE  67-­‐1990   Utilities     Test,  Inspection   NV   per  NFPA,  OSHA,  IEEE   criteria   D2.UTILITY.KL.01   1.1.1   DR22.1   CR22   NFPA  70.285;  OSHA  29  CFR   1910.269;  IEEE  1-­‐1986   Utilities     Test,  Inspection   NV   per  NFPA,  OSHA,  IEEE   criteria   D2.UTILITY.KL.06   1.1.2   DR22.2   CR16   NFPA  99;  OSHA  29  CFR   1910.269;  IEEE  32-­‐1972   Utilities     Inspection   NV   per  NFPA,  OSHA   criteria   D2.UTILITY.KL.07   1.1.3   DR22.2   CR17   OSHA  1910.335   Utilities     Test,  Inspection   NV   per  OSHA  criteria   D2.SYSTEM.TD.06   1.1.4   DR22.2   CR12   IEEE  389-­‐1996   Operations   Calculation,  Test   NV   per  IEEE  criteria   D2.UTILITY.KL.01   1.2.1   DR22.3   CR22   OSHA  1926.416   Operations   Analyses,  Test,   Inspection   NV   As  stated  in   requirement  text   D2.SYSTEM.TD.01   1.2.2   NA   CR11   Stakeholder  Defined   Operations   Calculation,  Test   NV   As  stated  in   requirement  text   D2.SYSTEM.TD.11   2.1.1   DR14.1   CR6   OSHA  1910.307   Operations   Design  Review  of   calculations,  Test   NV   As  stated  in   requirement  text   D2.SYSTEM.TD.15   2.1.2   NA   CR10   Stakeholder  Defined   Operations   Design  Review  of   calculations,  Test   NV   Calculation  specifies   Req  2.1.2  as  input   D2.WIRE.CV.03   D2.WIRE.CV.06   2.2.1   DR8.3   CR14   CR15   Stakeholder  Defined     Operations   Design  Review,  Test   NV   As  stated  in   requirement  text   Req.  D2.SYSTEM.TD.15   2.3.1   NA   CR10   Stakeholder  Defined     Operations   Analyses,  Test   NV   As  stated  in   requirement  text   Req.  D2.  OPERATOR.BD.04.1   2.3.2   DR21.1   CR2   EPA  NESHAP   Operations   Inspection   NV   per  NESHAP  criteria   Req.  D2.UTILITY.KL.05   2.3.3   DR21.2   CR21   NFPA  80   Sustainment   Test,  Inspection     NV   per  NFPA  criteria     Req.  D2.LIFE.AS.05.1   3.2.1   DR12.1   CR18  
  • 37. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 7   ~ Table 9- 10 WRS Traceability Functional Decomposition Original Customer Requirement Derived Requirements 1.1.1 Convert Power CR22 DR22.1 1.1.2 Surge Protect CR17, CR9, CR11 1.1.3 Ground Power CR16, CR11 1.1.4 Distribute Power CR22 DR22.2 1.2.1 Cool Electronics CR22 DR22.3 1.2.2 Remove Exhaust/Particulate CR21 DR21.1 2.1.1 Receive Wire Path Design CR3 2.1.1.1 Translate Design to Route CR6 DR14.1 2.1.2 Receive Wire CR8 DR.8.1 2.1.3 Receive Start/Stop CR1 2.1.3.1 Activate Device CR1 2.1.3.2 Deactivate Device CR1, CR9 2.2.1 Navigate Wire in 3D Space CR8, CR14 2.2.1.1 Deliver Wire along path CR15, CR14 2.2.1.2 Allow for Grouping CR15 2.2.3 Support Routed Wire CR8 DR8.2 2.2.2 Deploy Wire CR14, CR15 DR8.3 2.3.1 Communicate Messages CR4, CR5, CR10 2.3.2 Accommodate Removal of Wire CR2 2.3.3 Remove Debris/Waste CR21, CR13 3.1.1 Capable of Receiving Service CR7 3.1.1.1 Calibration Capable CR20, CR7 3.1.1.2 Capable of Receiving Lubricant CR7 DR7.1 3.1.1.3 Programmable Software CR7, CR19 DR19.1 3.1.2 Capable of Receiving Repairs CR7 3.1.2.1 Replaceable Interchangeable Parts CR7, CR12 DR7.2 3.2.1 Decomposable Modules CR12, CR18 3.2.1.1 Mechanically & Electrically Separable CR12, CR18 DR12.1 3.3.1 Utilize Recyclable Material CR21 DR21.2 3.3.2 Use Reusable Parts CR21 DR21.3 1.2 Ventilate Components 1.1 Receive Power 1 Utility Wire Routing System Requirements Traceability 3.3 Environmentally Friendly 3.2 Transportable Components 3.1 Maintainable Functionality 3 Sustainment 2.3 Produce Output 2.2 Route Wire 2.1 Receive Input 2 Operation
  • 38. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 8   ~ 9.5 Appendix  V  Market  Research   Table 9-11 Technology Impact Matrices Receive  Wire  Path  Design  TIM            Ref  2.1.1         Technology     MOE   %  Relative   Importance  Weight   Wired  Network   USB  2.0/3.0   Cloud  Based   Totals    Accuracy/Repeatability   0.31   6   9   6   21    Simplified  User  Operation   0.1   9   9   6   27    Increased  Reliability   0.2   9   6   3   21    Low  Operating  Cost     0.28   9   9   6   3    Technology  Readiness  Level   0.11   9   9   9   27         Weighted  Sums   8.07   8.4   5.73   22.2       Total  Percent  Weight   36%   38%   26%   100%                  Receive  Wire  TIM              Ref  2.1.2       Technology       MOE   %  Relative   Importance  Weight   Gear  Wheel   Straightener   Bearing  Wheel   Straightener   Conveyorless   Crank  Wheel   Totals   Accuracy/Repeatability   0.31   9   9   6   3   27   Simplified  User  Operation   0.1   9   9   9   3   30   Increased  Reliability   0.2   9   9   6   1   25   Low  Operating  Cost     0.28   7   6   9   1   23   Technology  Readiness  Level   0.11   9   9   9   9   36       Weighted  Sums   8.44   8.16   7.77   2.9   27.27     Total  Percent  Weight   31%   30%   28%   11%   100%                Route  Wire  TIM              Ref  2.2       Technology           MOE   %  Relative   Importance  Weight   Belt  Driven    Linear  Ball  Slide   Manual  Peg   Board   Totals    Accuracy/Repeatability   0.31   6   9   3   18    Simplified  User  Operation   0.1   6   6   1   13    Increased  Reliability   0.2   6   6   1   13    Low  Operating  Cost     0.28   9   9   1   19    Technology  Readiness  Level   0.11   9   9   9   27         Weighted  Sums   7.17   8.1   2.5   17.77       Total  Percent  Weight   40%   46%   14%   100%                                Receive  Input  TIM              Ref  2.1       Technology       MOE   %  Relative   Importance  Weight   Form  Based     Capacitive  Touch  HMI   Command  Line   WIMP/GUI   Totals   Accuracy/Repeatability   0.31   9   6   9   6   30   Simplified  User  Operation   0.1   9   3   1   9   22   Increased  Reliability   0.2   9   1   9   9   28   Low  Operating  Cost     0.28   3   9   1   6   19   Technology  Readiness  Level   0.11   9   3   9   6   27     Weighted  Sums   7.32   5.21   5.96   6.9   25.39     Total  Percent  Weight   29%   21%   23%   27%   100%                Accommodate  Removal  of  Wire  TIM            Ref  2.3.2       Technology           MOE   %  Relative   Importance  Weight   Operator  Based   Modular  Equipment   Mechatronics   Totals      Accuracy/Repeatability   0.31   3   9   12      Simplified  User  Operation   0.1   6   9   15      Increased  Reliability   0.2   6   6   12      Low  Operating  Cost     0.28   1   9   10      Technology  Readiness  Level   0.11   9   6   15         Weighted  Sums   3.34   8.07   11.41         Total  Percent  Weight   29%   71%   100%      
  • 39. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   3 9   ~ Table 9-12 Technology Options Ref.  1.1  Technology  Options               Ref.  1.1  Power  Supply  Technology   Technology  Attribute   Induction  Motor   Brushless  Motor   Brushed  Universal   Motor   Natural  Gas   Solar   Standard  US   Electrical  Receptacle   Control  Requirement   Optional   Always     Optional   Always   Always   None   Typical  Drive   AC   DC   DC   N/A   N/A   AC   Maintenance   None     None   Periodic   Periodic   Periodic   None   Efficiency     High   High   Moderate   High   High   Moderate   Manual   Activation/Deactivation   Yes   Yes   Yes   Yes   Yes   Yes   Power  Factor   Low/Moderate  (0.5-­‐0.95)   N/A   Moderate  (0.94)   N/A   N/A   Moderate  (0.9)   Accuracy/Repeatability   High   High   High   High   Varies   Moderate/High   Simplified  User  Operation   Yes   Yes   Yes   Yes   Yes   Yes   Reliability   High   Moderate/High   High   Moderate/High   Varies   Varies   Cost     Low   High   Moderate     Low   High   Low   Existing  Technology   Yes   Yes   Yes   Developing   Developing   Yes   Technology  Readiness  Level   9   9   9   3   5   9                Ref.  1.2.2  Technology  Options               Ref.  1.2.2  Remove  Exhaust/Particulate  Technology        Technology  Attribute     Self  Dumping  Hopper   Manual   Ventilation  Exhaust        Effectiveness   Moderate/High   Low   High        Automated  Wire  Cutting   Varies   None   Varies        Maintenance   Moderate   High   Moderate        Conveyor  Belt  Specific   Varies   No   Varies        Accuracy/Repeatability   Low   Low   High        Simplified  User  Operation   Low   Low   High        Reliability   Low   Low   High        Cost     Moderate/High   Low   Moderate/High        Existing  Technology   Yes   Yes   Yes         Technology  Readiness  Level   9   6   9                      Ref.  2.1.1.1  Technology  Options               Ref.  2.1.1.1  Translate  Design  to  Route  Technology      Technology  Attribute   SolidWORKS   Rhino   Pro/Engineer   LeapMotion       Commercial-­‐Off-­‐The-­‐Shelf   Yes   Yes   Yes   Yes      3D  Capable   Yes   Yes   Yes   Yes       Augmented  Reality  Capable   No   No   No   Yes      Maintenance   Low   Low   Low   Moderate      Accuracy/Repeatability   High   High   High   Low/Moderate      Simplified  User  Operation   Low   Low   Low/Moderate   Low/Moderate      Reliability   High   High   High   Low/Moderate      Cost     High   High   High   High       Existing  Technology   Yes   Yes   Yes   Developing       Technology  Readiness  Level   9   9   9   3      
  • 40. Wire Routing System (WRS) Systems Engineering Management Plan _____________________________________________________________________________ ~   4 0   ~ Figure 9.5 Work Breakdown Structure W2 Sys Engineering W2.2 Personnel W2.2.1 Team Lead W2.2.2 Electrical Lead W2.2.3 Mechanical Lead W2.2.4 Software Lead W2.2.5 Drafter W2.3 Research & Development W2.3.1Technol ogy W2.3.2 Procurement W1 Project Mgmt W1.1 Personnel W1.1.1 Project Manager W1.1.2 Financial Planner W1.1.3 Procurement Manager W1.1.4 Vendor Oversight W1.2 Facilities W1.2.1 Property W1.2.2 Equipment W3 Interface Systems W3.1 Development W3.2 Testing of Software Module W3.2.1 Unit Hardware Test W3.2.2 Integration W3.2.3 System Test W4 Control System W4.1 Control Theory Analysis W4.2 Process Control Software Development W4.2.1 Algorithm Development W4.2.2 Process evaluation W6 Management Reserve W6.1 Risk mitigation funding W6.1.1 Quality risk W6.1.2 Cost risk W6.1.3 Schedule risk W7 Assembly and Test W7.1 Facility W7.1.1 Development of facility requirements W7.1.2 Facility design W7.1.3 Modify/ build to design W7.2 Assembly and test equipment W7.2.1 Standard tools W7.2.2 Specialty tools W7.3 Assembly and test personnel W7.3.1 Internal (WRS personnel) W7.3.2 External (component supplier SMEs) W8 Sustainment W8.1 Develop maintenance manuals W8.1.1 Recommended maintenance schedules W8.1.2 Maintenance procedures W8.2 Develop repair manuals W8.2.1 Recommended spare parts list and quantities W8.2.2 Repair procedures W8.3 Develop training curriculum W8.3.1 Initial live skills training and certification W8.3.2 Refresher training and recertification W8.4 Sustainment team W8.4.1 Update manuals W8.4.2 Ensure availability of parts W8.4.3 Update training W5 Mechanical System W5.1 Design hardware components W5.1.1 Wire deposit hardware W5.1.2 Wire capture hardware W5.1.3 Wire handling hardware W5.1.4 Utility hardware W5.1.6 Build hardware components W5.1.7 Wire deposit hardware W5.1.8 Wire capture hardware W5.1.9 Wire handling hardware W5.1.10 Utility hardware W5.2 V&V W5.2.1 Design V&V W5.2.2 Build V&V W5.3 Component Integration W5.3.1 Design of integration points W5.3.2 Interface W5.3.3 Control W5.3.4 Mechanical W5.3.5 Subcontract/ vendor systems W5.4 Coordination of integration design W5.4.1 Internal coordination W5.4.2 External coordination W1 Project Mgmt W2 Sys Engineering W3 Interface Systems W4 Control System W5 Mechanical System W6 Management Reserve W7 Assembly and Test W8 Sustainment W1.1 Personnel W1.1.1 Project Manager W1.1.2 Financial Planner W1.1.3 Procurement Manager W1.1.4 Vendor Oversight W1.2 Facilities W1.2.1 Property W1.2.2 Equipment W2.2 Personnel W2.2.1 Team Lead W2.2.2 Electrical Lead W2.2.3 Mechanical Lead W2.2.4 Software Lead W2.2.5 Drafter W2.3 Research & Development W2.3.1Technol ogy W2.3.2 Procurement W3.1 Development W3.2 Testing of Software Module W3.2.1 Unit Hardware Test W3.2.2 Integration W3.2.3 System Test W4.1 Control Theory Analysis W4.2 Process Control Software Development W4.2.1 Algorithm Development W4.2.2 Process evaluation W5.1 Design hardware components W5.1.1 Wire deposit hardware W5.1.2 Wire capture hardware W5.1.3 Wire handling hardware W5.1.4 Utility hardware W5.1.6 Build hardware components W5.1.7 Wire deposit hardware W5.1.8 Wire capture hardware W5.1.9 Wire handling hardware W5.1.10 Utility hardware W5.2 V&V W5.2.1 Design V&V W5.2.2 Build V&V W5.3 Component Integration W5.3.1 Design of integration points W5.3.2 Interface W5.3.3 Control W5.3.4 Mechanical W5.3.5 Subcontract/ vendor systems W5.4 Coordination of integration design W5.4.1 Internal coordination W5.4.2 External coordination W6.1 Risk mitigation funding W6.1.1 Quality risk W6.1.2 Cost risk W6.1.3 Schedule risk W7.1 Facility W7.1.1 Development of facility requirements W7.1.2 Facility design W7.1.3 Modify/ build to design W7.2 Assembly and test equipment W7.2.1 Standard tools W7.2.2 Specialty tools W7.3 Assembly and test personnel W7.3.1 Internal (WRS personnel) W7.3.2 External (component supplier SMEs) W8.1 Develop maintenance manuals W8.1.1 Recommended maintenance schedules W8.1.2 Maintenance procedures W8.2 Develop repair manuals W8.2.1 Recommended spare parts list and quantities W8.2.2 Repair procedures W8.3 Develop training curriculum W8.3.1 Initial live skills training and certification W8.3.2 Refresher training and recertification W8.4 Sustainment team W8.4.1 Update manuals W8.4.2 Ensure availability of parts W8.4.3 Update training WRS