Project Kick-Off. External Supervisory Interface for Process Automation

1. Project Kick-Off

External Supervisory Interface for Process Automation

2. Agenda

Introduce project
Acceptance criteria
Project description
Customer, sponsor,
stakeholders, and project
team members
Assumptions, constraints,
and challenges
Rules of engagement
Etiquette
Scope, timeline, and budget
Communication
Make-or-buy
Workflow
Hardware and Software
Testing
Test articles, test stands, test
documents, and test software
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Assignment of duties and
responsibilities

3. Project Overview

The project of External Supervisory Interface for
Process Automation has the purpose of providing realtime supervisory tool for QC engineers team
The project execution will include software
development, security audit and interface usability
analysis
The possibility of remote supervising the manufacturing
process will decrease quality issues reports by 5 times
according to collected and analyzed statistical data.
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4. Customer, Sponsor, and Stakeholders

The customer: The Head of Automotive
manufacturing unit has pointed out the necessity of
implementing 6 sigma management in order to
reduce quality issues.
Sponsor: Automotive Business Unit with corporation
as the most sensitive to deviations in process in terms
of final product quality.
Stakeholders (all are internal):
Head of procurement EMEA region
Head of Automotive EMEA region
Head of Manufacturing site in Russia
Head of IT EMEA region
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5. The Project Team

ID project team members
Project Management: Denys Ivanov
Designer: Head of QC Lab
Engineering: IT architecture manager
Purchasing, Contracts: head of procurement Russia
Quality: Head of IT Russia, Head of QC lab
Operations: CS solutions (outsourcing), IT team, QC engineers, Manufacturing
team engineers
Human resources: HR engineer
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6. Project Scope

The Project Scope includes:
What: QC will be improved with the help of remote interface
supervising materials preassembling and manufacturing process.
Where: Manufacturing site in Russia
How: To implement secure and usable interface to supervise all
steps of manufacturing process
Who: The team will include internal resources, outsourcing. End
users: QC engineers.
Why: The purpose of the project is to reduce issues with quality
and thus to increase production capacity of installed equipment.
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7. Timeline

Provide top level milestones
Item
Description
Estimated
Date (ECD)
1
2
3
4
5
6
7
Project Requirements
Preliminary security audit review
Final Design Review
Detail Designs Complete (Objective 1)
Implementation of Objectives 2, 3 and 4
Debug & Tests (Objective 5)
Go Live of Objective 6
Week 1
Week 2
Week 3
Week 4
Week 8
Week 12
Week 13
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Completion

8. Budget

Initial Cost estimated for system – 870,000 USD
Security audit support – 15,000 USD monthly
SW upgrade support and changes implementation – 120,000 USD
annually
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9. Make – or – Buy [Alternatives]

Additional extensive training
of production team
Costs expected: 600,000 USD
annually
Adding dedicated QC lab
engineer in production to
each line
Time to hire and train: 15
months (3,200,000 USD
potential lost)
Efficiency rate is not clear.
Salary increase effect –
840,000 USD annually
Savings: 1,560,000 USD
annually
Additional costs: 560,000 USD
annually
EHS insurance: 75,000 USD
annually.
Savings: 2,550,000 USD
annually
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10. Test and Validation

Top level test and validation
Test articles
Allan Bradley controller
Data transferring SW
Test plan & Procedures
Security validations
Interface usability
Correct data adapting
Monthly security audit
Weekly prototypes evaluations
Test acceptance criteria
Unauthorized access cases -> 0
Performance: real-time delays < ½ sec
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11. Customer Acceptance Criteria

Customer acceptance criteria
Customer review and approvals
Prototype approval
User interface usability approval
Performance and security audit positive reports
Final adjustments and deploying in production environment
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12. Assumptions and Constraints

Assumptions
The external interface will not
control the production and can be
used only for supervising. For
interfering, separate channel of
communication with manufacturing
team must be used.
No dedicated employee will be
needed to watch the dashboard. QC
lab has enough resources.
User Interface will resemble control
panels interface in production in
read-only mode.
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Constraints
Due to extended demands to
security, the module development
will require expensive resources.
Even after most thorough tests and
debug process, we still reserve
some time for problems solving in
production within 6 weeks of
operations.

13. Challenges

ID challenges that may be associated with the project
Internal challenges
Properly designed UI and performance for QC engineer to supervise the
process
External challenges
To exclude any possibility of unauthorized access to the system
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14. Rules of Engagement

Etiquette
Communication
Updates – on weekly basis
Status reports – after each milestone
Actions – actions plan submitted to heads of departments on weekly basis
Meetings
Communication – emails, phone, meetings, and others
Kick Off meeting, by PM
Prototype review and acceptance meetings by IT
Status reports meetings by PM
Workflow
9-00 a.m. short meeting
Weekly: each Wednesday, 10-00 a.m. – 11-00 a.m.: progress review
By milestones completion – status review
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15. Assignment of Duties and Responsibilities

Resources
Activity
Administrator
Business
analytic
System
integrator
IT
Initial business data collecting
C
R
I
C
Technical task composing
A
R
R
C
Working prototype deploying
C
A
I
R
System trials and adjustments
I
R
I
A
Deploying operational system in production
A
I
C
R
R
A
C
I
Responsible
Accountable
Consult
Inform
Legend
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