Proceedings of he 8h Inernaional Conference on Innovaion & Managemen 463 Projec Managemen Incorporaing Dynamic Simulaion & TRIZ Toshihiro Ioi 1, Seiichiro Haa 1, Shigeru Nagami 2, Hiroshi Okuhara 2 1 Deparmen of Projec Managemen, Chiba Insiue of Technology, Chiba, Japan 2 Fasoec Company Ld., Chiba, Japan (E-mail: oshihiro.ioi@i-chiba.ac.jp, s1191018cx@i-chiba.ac.jp, nagami@fasoec.co.jp, okuhara@fasoec.co.jp ) Absrac: This paper proposes a mehod for refining a requiremens definiion in projec managemen ha incorporaes dynamic simulaion. Many sudies have been repored on requiremens definiions in projec managemen, bu here are few sudies ha use dynamic simulaion and examine he refining of a requiremens definiion. A requiremens definiion for a manufacuring projec is expeced o be refined if bolenecks in he producion process are recognized and if soluions o hem are fed back ino he definiion. This paper proposes a mehod for refining a requiremens definiion for a manufacuring projec wih dynamic simulaion (DELMIA), heory of invenive problem solving (TRIZ), heory of consrains (TOC), and design o cusomer needs (DTCN). Key words: definiion; Projec managemen; Dynamic simulaion; Design o cusomer needs; TRIZ 1 Inroducion An imprecise requiremens definiion is one cause of projec failure. In order o lead a projec o success, i is imporan o examine a mehod for developing a requiremens definiion ha is based on close communicaions wih cusomers. This requires idenifying cusomer needs accuraely, invesigaing he feasibiliy of accommodaing hose needs in a projec, and refining a requiremens definiion. Many sudies have been repored on a requiremens definiion in projec managemen [1]-[3]. However, here are few sudies on requiremens definiion managemen ino which dynamic simulaion (DELMIA) [4], heory of consrains (TOC) [5], heory of invenive problem solving (TIPS in English, TRIZ in Russian) [6], and design o cusomer needs (DTCN) [7] are incorporaed and inegraed on he basis of he socializaion, exernalizaion, combinaion, and inernalizaion (SECI) process, which is a mehod of knowledge creaion. A requiremens definiion for a manufacuring projec is expeced o be refined if bolenecks in he producion process are accuraely prediced and if such predicions are fed back ino he definiion. This paper examines a framework for managing a requiremens definiion wih dynamic simulaion and TRIZ. 2 Framework for s Definiion Managemen In developing a requiremens definiion for a projec, i is imporan o share value judgmens involving he projec wih cusomers. This requires idenifying cusomer needs and invesigaing he feasibiliy of accommodaing hem in he projec. The auhor and collaboraors have repored on a mehod for refining a requiremens definiion wih DTCN [1]. However, he main focus of DTCN is on accuraely idenifying cusomer needs, and lile consideraion is given o he feasibiliy of accommodaing hem. This paper aemps o refine a requiremens definiion by inroducing dynamic simulaion ino DTCN and aking ino accoun he feasibiliy of accommodaing cusomer needs in a projec. Figure 1 shows a framework for requiremens definiion managemen incorporaing dynamic simulaion. The requiremens definiion managemen is based on he SECI process, which is a mehod of knowledge creaion [5]. In he socializaion phase, according o he definiion of he SECI process, aci knowledge is creaed hrough he five senses; in his paper, bolenecks in a producion process are foreseen hrough simulaion analysis on manufacuring ime and ask processes wih DELMIA. In he exernalizaion phase, designs are creaed hrough conversaions and hinking; in his paper, proposed cusomer requess are horoughly examined wih TRIZ. In he combinaion phase, new knowledge is creaed hrough combinaion of formal knowledge; in his paper, requiremens clarified hrough TRIZ are combined based on he conceps of "cloud" and "branch" in TOC and are capured as knowledge o be used for eliminaing he bolenecks in he manufacuring process. Consequenly, in he inernalizaion phase, DTCN makes i possible o obain knowledge on he requiremens definiion ha accommodaes cusomer needs. Also, by running he SECI process, one can expec o "spiral up" knowledge for designing a requiremens definiion. In addiion, he requiremens definiion managemen
464 Proceedings of he 8h Inernaional Conference on Innovaion & Managemen model can be evaluaed quaniaively wih a mauriy model. Framework for he Definiion using Dynamic Simulaion & TRIZ S Dynamic Simulaion DELMIA I PMD DTCN Technique Procedure Creaion Image Creaion Idea Creaion Exracion Phase Sep Lis WBS FBS Real World Exracion of TRIZ World Absracion Exracion of Conradicion TRIZ TOC E Definiion Embodimen 40 Invenion Principles C Recogniion of Boleneck Turge Tree Definiion Evaluaion Phase R D 3 M A A Goal Level of Definiion B C B Iniial (1) Goal Level of Definiion C Opimized (5) Managed (4) Defined (3) Repeaable (2) High Low S : Socializaion, E : Exernalizaion, C : Combinaion, I : Inernalizaion, DTCN : Design To Cusomer, PMD : Purpose Measure Diagram, TOC : Theory Of Consrain, TRIZ : Teoriya Resheniya Izobreaelskikh Zadach, : Definiion Managemen Mauriy Model Figure 1 Framework For s Definiion Managemen Incorporaing Dynamic Simulaion 3 Process for Developing a s Definiion 3.1 Dynamic simulaion To ascerain he appropriaeness of a producion process, his paper uses simulaion ools, DELMIA and QUEST [6]. The use of DELMIA makes i possible o discover process risks a an early sage, display performance relaive o arge values, plan a highly precise process by reusing an empirically proven process, and reduce he ime for planning he process. Wih he use of QUEST i is possible o assess siuaions surrounding a manufacuring process, such as he level of worker faigue, from an ergonomic perspecive. Figure 2 shows a producion process for an auomobile par, which is simulaed wih he use of DELMIA and QUEST. Using he dynamic simulaion ools, one can undersand he producion process, compare i wih an experience-based producion plan, and evaluae he appropriaeness of he process. Manufacuring Process Analysis by DELMIA Basic Iems in Manufacuring Projec Managemen 1. Problems & heir Soluions on he Manufacuring Planning carried ou frequenly. 2. Definiion in he Manufacuring Projec is also carried ou frequenly a he Same Paern. 3. I is necessary o inroduce he Scienific Technique (DELMIA TRIZ TOC DTCN) for he PM Innovaion. 1 Dynamic Simulaion (DELMIA) 1 Dynamic Simulaion (DELMIA) 3 Theory of Consrain(TOC) 2 Teoriya Resheniya Izobreaelskikh Zadach (TRIZ) 1 2 3 4 4 Design o Cusomer (DTCN) Sysemaizaion for Theorizaion of Basic Poin by Problem Soluion Technique Figure 2 A Producion Process for an Auomobile Par which is Simulaed wih he Use of DELMIA Because of mass producion, producion arges for auomobile pars are se based on experience,
Proceedings of he 8h Inernaional Conference on Innovaion & Managemen 465 and he problem has arisen ha he feasibiliy of accommodaing cusomer needs in a projec is uncerain. To dynamically simulae a manufacuring process, DELMIA and QUEST are used o simulae he number of operaing days/hours, quaniy produced, shifs, ac ime, he number of direc workers, cycle ime, he worker uilizaion rae, value produced, and he number of worksaions. Simulaion analyses on producion plans are conduced, and he curren producion plan and he simulaion resuls are compared. This reveals ha iniial plans lead o a significanly increased number of processes and greaer coss, which makes i possible o calculae appropriae condiions for daily producion operaion ha are consisen wih producion arges. Table 1 shows an example of he resul of a simulaion using DELMIA and QUEST for he producion process. Table 1 An Example of The Resul of A Simulaion Purpose : Evaluaion of Producion Plan Based on Producion Planning using DELMIA & QUEST of Simulaion Tool Resul : I is Difficul o Achieve he Producion Plan. I will be Grealy Increased he Operaion Hours. Number of Producion/Day= Number of Producion// Operaion Day Tac Time =Operaion Hour/Day/Producion Quaniy Iems Plan シミュレーション Ver. 1 Ver. 2 Ver. 4 Uni Operaion Day 20 20 20 20 Day/Monh Operaion Hour 7.5 7.5 7.5 7.5 Hour Shif 2 2 2 2 - Number of Producion 1250 1019 1000 1011 Piece/Day Tac Time 43.20 53.00 54.00 53.40 sec Number of Direc Operaor 5 5 5 5 Person Number of Indirec Operaor Person Cycle Time 217 238 249 249 sec Operaion Raio of Operaor (Average) 89.5 95.5 95 % Earned Value 83 68 67 67 Piece/Hour Number of Operaion Desk 10 10 10 10 3.2 Invenive problem solving Eliminaion of bolenecks in a producion process requires undersanding he characerisics of he process, such as he coss and ime required for producion, and examining measures for improvemen based on hem. In his paper, afer he simulaion analysis wih DELMIA and QUEST, facors in bolenecks in a producion process are analyzed by TRIZ [7]. Figure 3 illusraes a TRIZ-based facor analysis of producion process bolenecks. TRIZ is applicable o Levels 2 and 3 where complicaed inconsisencies can be overcome and correcions can be made. In a manufacuring projec, i is ofen he case ha process bolenecks are found on he basis of experience, ha ways o reduce or eliminae he bolenecks are examined, and ha measures are implemened in he acual manufacuring process (Figure 4, op). In conras, in TRIZ, producion-relaed inconsisencies are idenified afer manufacuring process bolenecks are found. Focus is hen shifed from realiy o he world of TRIZ, where 40 invenion principles are convered o keywords for refining a requiremens definiion, and facors in he bolenecks are analyzed. The boom able in Figure 4 shows some examples of he keywords for analyzing facors of bolenecks, which are convered from he 40 invenion principles.
466 Proceedings of he 8h Inernaional Conference on Innovaion & Managemen Problem Soluion of Manufacuring Planning by TRIZ Inroducion Level 2 Teoriya Resheniya Izobreaelskikh Zadach Level of TRIZ Applicaion Level of TRIZ No Applicaion of TRIZ:Effec Applicaion of TRIZ:Effec Applicaion of TRIZ:Effec Applicaion of TRIZ:Effec No Applicaion of TRIZ : Effec Level 5 Level 4 Level 3 Level 2 Level 1 Real Discovery Soluion by Principle of Same Caegory of Business Improvemen by Conques of Difficul Conradicion Improvemen by Conques of Conradicion Lile Improvemen wihou Conradicion Figure 3 A TRIZ-based Facor Analysis of Producion Process Bolenecks 3.3 Theory of consrains and a mehod for designing a mechanism o accommodae cusomer To examine he appropriaeness of a manufacuring process, i is imporan o clarify necessary condiions for achieving manufacuring objecives, using TOC [8]. The use of TOC makes i possible o undersand core problems in a manufacuring process, foresee remedies and pos-remedy condiions, and see obsacles clearly. Also, using he concep of "cloud" in TOC, one can no only clarify goals in common beween cusomers and he projec eam and wheher such goals should be fulfilled, bu also shif emphasis away from a problem in he form of cusomers versus a projec eam o a problem for boh cusomers and a projec. Furhermore, using he concep of "branch" in TOC, one can analyze causal relaions among phenomena wih if-hen logical saemens. I hen becomes possible o undersand why acions of boh cusomers and a projec mus be changed and o implemen necessary measures responsibly. In addiion, his paper uses he work breakdown srucure phasing heme echnique in DTCN and proposes a mehod for developing a requiremens definiion ha saisfies boh cusomer needs and feasibiliy condiions for accommodaing hem (Figure 5). Real World Boleneck Soluions TRIZ World Absracion Embodimen Exracion of Conradicion 40 Invenion Principles Example of Transformaion from Invenion Principles o Soluion of Boleneck Division Classificaion of Cusomer Combinaion Combinaion of Cusomer Reacion Recogniion of Acual Problem Separaion Move o Oher Generaliy Concurren Operaion Operaion Predicion he Difficuly Limied Par Feaure Change Each Oher of One Poin Nesing WBS & Work Package Proecion Backup of he Imporan Informaion Asymmery No Adjus of Unnecessary Poins Balance Take he Balance for he Cusomer Equal Poenial Loosen for Cusomer Figure 4 Problems Soluion by TRIZ
Proceedings of he 8h Inernaional Conference on Innovaion & Managemen 467 3 Theory of Consrain Manufacuring Planning Analysis by TOC Basic Iems in Manufacuring Projec Managemen 1. Problems & heir Soluions on he Manufacuring Planning carried ou frequenly. 2. Definiion in he Manufacuring Projec is also carried ou frequenly a he Same Paern. 3. I is necessary o inroduce he Scienific Technique (DELMIA TRIZ TOC DTCN) for he PM Innovaion. PM Review of he Projec by he Siuaion of Ousider WBS Phasing Cusomer TOC TOC DELMIA TRIZ Mauriy Model Sysemaizaion for Theorizaion of Basic Poin by Problem Soluion Technique Figure 5 Problems Soluion by TOC & DTCN Technique 3.4 Examinaion of requiremens definiion managemen This paper proposes a mehod o find and eliminae bolenecks in a manufacuring projec, using dynamic simulaion, TRIZ, and TOC. The applicaion of he aforemenioned analyical resuls o DTCN makes i possible o develop a requiremens definiion for a manufacuring projec ha can fulfill cusomer needs and achieve he accommodaion of hem in he projec. Figure 6 shows he resul of examining requiremens definiion managemen for an auomobile par manufacuring projec. Through he use of TRIZ, TOC, and DTCN, i is possible o undersand he difference beween he manufacuring process buil on experiences and he resul of DELMIA simulaion. Evaluaion for Definiion managemen Evaluaion Process 1 Producion Time by DELMIA 2 Direcionaliy of Producion Plan by TRIZ & 3 Boleneck of Producion Process by 4 Decision of Definiion for Cusomer by DTCN WBS Phasing Validiy of Producion Plan Direcionaliy for Problem Soluion Design To Cusomer Definiion Goal Improvemen of Produciviy Projec Manufacuring PM + Direcionaliy of Problem Soluion by Recogniion of hole Srucure Selecion of Soluion Increase of Cycle Time DELMIA TRIZ Cusomer Decrease of Turnover TOC ( ) Correspondency of Projec Mauriy Model Feedback Comparison wih Pas Projec by ELMIA Balance Tradeoff beween Cos & Number of Person Anicipaion Operaion (Risk Criical Ph) Improvemen of Operaion for Produciviy Exension of Operaion Time Decrease of Turnover Decrease of Produciviy Figure 6 Verificaion for s Definiion Managemen This paper proposes a requiremens definiion managemen mauriy model () o evaluae requiremens definiion managemen. The levels and he managemen process in he are shown
468 Proceedings of he 8h Inernaional Conference on Innovaion & Managemen in Figure 7. In a projec, a requiremens definiion has radiionally been refined hrough increased and improved communicaions wih cusomers, bu he definiion has no been horoughly evaluaed wih a mauriy model. s definiion managemen has been nohing more han wrien or repeaed processes. However, his paper finds ha he proposed mehod makes a managed process feasible and increases he mauriy of requiremens definiion managemen from Level 1 o Level 3. 4 Conclusions Examining projec managemen based on dynamic simulaion, his paper (1) proposes a requiremens definiion managemen model incorporaing DELMIA, TOC, TRIZ, and DTCN; (2) finds producion condiions in which cusomer needs and feasibiliy condiions for accommodaing hem in a projec are boh considered, as a resul of invesigaing he effeciveness of a requiremens definiion managemen model wih dynamic simulaion in he conex of a mass-producion projec for an auomobile par; and (3) reveals ha he mauriy of requiremens definiion managemen can be increased, as a resul of proposing a o assess requiremens definiion managemen and examining i in he conex of a projec for manufacuring an auomobile par. Mauriy Level for Definiion Managemen Immauriy No Objecive Way for Definiion Managemen Predicable Process Sandard, Consisen Process Disciplined Repeaable (2) Process Coninuously Improving Process Defined (3) Managed (4) Esablishmen of Conrol Managemen Process Opimized (5) Improvemen of Saisfacion of Projec Sakeholder Inegraion & Opimaizaion Definiion Execuion Evaluaion : Mauriy Way and Evaluaion wih Quaniaive Based Definiion Iniial (1) Individual Compaible Low Saisfacion of Projec Sakeholder Processes of Definiion Managemen Invesigaion DELMIA TRIZ TOC DTCN Framework for Definiion Managemen : Definiion Managemen Mauriy Model DB Figure 7 Definiion Managemen Mauriy Model Acknowledgmen The auhor hanks FASOTEC Co., Ld. for providing valuable informaion for conducing his sudy. References [1] Ioi T., Chaani Y. Research on Sake-Holder Managemen, A Proposal of Definiion Corresponding o Cusom [A]. ProMAC2008, CD Elecric Version, 2008 [2] M. Nakamoo, e.al. Evaluaion Mehod in Qualiy Improvemen of RFP in Definiion, Naional Conference of SPM, 2011 (in Japanese) [3] G. Liu. Sakeholder Managemen Supporing Mehod, Naional Conference. of SPM2011,2011(In Japanese) [4] Regisered Trademark by Dassaul Sysemes [5] hp://www002.upp.so-ne.ne.jp/oc-jp/index.hm [6] The Maerials for Menal Healh Research Group by Docomo Co. Ld & Wisdom Co. Ld, 2011 [7] M. Ezaki. New Projec Managemen Mehods[M]. ASCII Publicaion Office, 1997 (In Japanese)