Product development

Product development

Assessment item 2 — Individual case study

All students are to submit electronically – max file size
is 2Mb.
ASSESSMENT
Weighting:  35%
2
Length:  No set length
Introduction and Student Guide

This assessment item is to  be completed individually.

The case study simulates a project management scenario  where the student takes on the role of project
manager.  The case information is not complete so where necessary students will have to  argue the
pros and cons of any assumptions they make.

If necessary, students are expected to find relevant  information in the academic literature to justify
their answers and provide appropriate references.

The following information is provided to assist  students to develop their assessment solution:

  Product development case description
  Specific assessment questions that must be answered
  Information regarding the submission of the assessment
  Marking guide
Product Development Case Description
Background
CQVideo is a medium sized company that develops and manufactures industrial monitoring
equipment.  You are an employee of CQVideo and work as project manager in the product
development department. The people involved in this case are:

  You are Mr. Project, the project manager.
  Mr. Product is the Director of Product Development.
  Ms. Marketing is the Director of Marketing and Portfolio Management.
  Ms. Resource is the Human Resource Manager.
  Functional line managers in the research and development department.
  Engineers and members of your project team.
You have been leading a small team of experienced engineers conducting a technical feasibility study
to investigate if it is possible to modify one of  the company’s standard products to create a product
variant to satisfy the needs of the mining industry. The M1 Milestone Concept Review will be held on
Friday 5
th
September 2014. The project management mil estone concept review checklist is provided
below.

The Project Management Milestone Checklist for M1
1.   Are the marketing requirements agreed?
2.   Are project targets agreed (e.g. schedule, features and quality)?
3.   Has a feasibility study been successfully completed?
4.   Is the product concept selected and well understood?
5.   Are user product mock-ups circulated and reviewed with marketing?
6.   Are the product and production technologies selected?
7.   Have key components and suppliers been identified?
8.   Has the supply chain impact of a new product been reviewed?
9.   Is the project organisation agreed?
10.  Is the project team established and operational?
11.  Is any project teambuilding and leadership development required?
12.  Is any technical training of project members required?
13.  Is the project plan document reviewed within the project?
14.  Is the MS project schedule reviewed?
15.  Is the project budget established and approved?
16.  Have the project risks been assessed, mitigated and reviewed?
17.  What are the key risks and how are they mitigated?
18.  Are the appropriate resources identified and allocated to the project?
19.  Are key stakeholders identified?
20.  What are the quality assurance activities required?
21.  What are the quality metrics you propose to monitor and what are the control methods you
plan to use in your project?
The concept review is one of the milestones  in the company’s product development process.

The need for the new product has been identified by the marketing department lead by Ms. Marketing,
Director of Marketing and Portfolio Management. Ms. Marketing provided your small project team
with a product brief, outlining the special end user, sales and service requirements to supplement the
requirements already established for the standard  product. She also developed the business case for
the product.

Your team have come up with a unique and novel product concept. The concept satisfies the new
requirements perfectly. The feasibility work carried  out showed that the user requirements were sound
and that the technical complexity of the development was low.

Your team also estimates that there is a reduction in the Bill of Materials (BOM) for the new product
although you have not assessed this at this stage.

You and your team believe that you can develop the product with li mited resources and within the
timeframe requested by Ms. Marketing. The sales launch deadline is to be advised (TBA).
Milestones
The milestones your team will use are:
A.   M1 Concept review complete (At this point the system architecture and feasibility study will
be complete. A go/no-go decision for detailed  design will be made at this milestone).
B.   M2 Design review complete (At this point the overall design will be complete. A go/no-go
decision for procurement will be made at this milestone).
C.   P1 proto build start (An internal project review  confirming that the product prototype is able
to be manufactured with th e quality level expected.).
D.   P2 proto build start (An internal project review  confirming that the product prototype is able
to be manufactured with th e quality level expected).
E.   M3 Final Design review complete (At this point the product quality is verified based on the
product validation testing carried out on the last prototype. A go/no-go decision for
production ramp-up is made).
F.   M4 Launch review (A go/no-go decision depending if all business areas are ready for market
launch and 50 units are in stock). This is to be  the end of the project schedule, i.e. when the
50 units are in stock.
The system architecture of the product has been u sed as the basis for the project organisation and the
work breakdown structure. As the project manager you have accepted the tasks of creating the
compiled project schedule and allocating resources.

From discussions with Mr. Software, Mr. Mechanics, Mr. Electronics, Mr. Production and Mr.
Validation, very experienced manage rs and engineers, you have obta ined the following information:

1.   A partially complete work break down structure (WBS), resource estimates and some
dependencies provided in Table 1 below.

2.   In addition, Mr. Production provided you with th e Activity-In-the-Box (AIB) network diagrams in
Figure 1. You will need to interpret the AI B network diagram to complete the WBS.

Note that the following abbreviations are used in the table:
  Electronic Engineer (EE)
  Software Engineer (SW)
  Mechanical Engineer/Industrial Designer (ME)
  Test Engineer (TE)
  Production Engineer (PE)
  Technical Writer (TW)
  Printed Circuit Board (PCB)
  Electromagnetic Compliance (EMC)

Table 1- Work Breakdown Structure
Activity  Description  Predecessor(s)
Relationships
Person days/weeks of
effort (and type of
resource required.)
To be
completed at
the following
milestone
1 Product development
1. 1   Electronics
1.1.1 PCB design   PCB design   M1

2 person-weeks of
EE.

1.1.2  Component selection  Selection of electronic
components.
1.1.1   1 person-week of EE.  M2
1.1.3 P1 circuit design improvements Electronic improvements to
circuit diagram, component
selection and layout.
1.1.1 2 person-weeks of
EE.
M2
1.1.4 P1 electronics verification
tests
Electronic verification tests
with the use of the P1
prototypes.
1.1.3, P1 build
complete
3 person-weeks of
EE.
P2
1.1.5 P2 circuit design improvements

Electronic improvements to
circuit diagram, component
selection and layout.
1.1.4  1 person-week of EE.
1.1.6 P2 el ectronics verification
tests
Electronic verification tests
with the use of the P2
prototypes.
1.1.5, P2 build
complete
3 person-weeks of one
EE.
M3
1.1.7 Thermal verification tests  Verification that electronic
heat generation and heat
transmission through covers
is acceptable.
1.1.5, P1 build
complete, P2
build
complete
3 person-days of EE.  M3
1.1.8 EMC verification tests  Verification of compliance
with electromagnetic
compliance regulations.
1.1.7, P1 build
complete, P2
build
complete
3 person-days of EE.  M3
1.2.  Software
1.2.1 Software specifications and
design
Specification of the
software functionality based
on user requirements.
M1  18 person-days of SE.  M2
1.2.2 User interface additions  Software additions due to
modified menus and
functional keys.
1.2.1  6 person-days of SE.
1. 2.3 Data storage additions  Software additions for data
storage.
1.2.1  4 person-days of SE.
1. 2.4 Device to PC protocol
additions
Software additions to the
communication protocol
between the device and the
PC.
1.2.1  4 person-days of SE.
1. 2.5 PC software additions  Software
additions/modifi cations to
the PC software
functionality to support the
new device functionality.
1.2.3, 1.2.4  6 person-days of SE.
1. 2.6 R1 release creation  Creation of the R1 software
release used for the P1
prototype build.
1.2.2, 1.2.3,
1.2.4, 1.2.5
3 person-days of SE.
1. 2.7 R1 release tests  Testing of the R1 release
and identification of errors.
1.2.6  12 person-days of SE.
1.2.8 R1 error correction and user
interface improvements
Creation of the R1 software
release used for the P1
prototype build.
1.2.7  18 person-days of SE.  P1
1. 2.9  R2 release creation  Creation of the R2 software
release used for the P2
prototype build.
1.2.8  3 person-days of SE.
1.2.10 R2 release tests  Testing of the R2 release
and identification of errors.
1.2.9, P1 build
complete
12 person-days of SE.
1.2.11 R2 error corrections  Correct ion of errors  1.2.10  18 person-days of SE.
1.2.12 R2 interoperability tests  Testing of interoperability
with 3
rd
party accessory
1.2.11  9 person-days of SE.
devices.
1.2.13 R2 interoperability error
correction
Correction of errors  1.2.12  18 person-days of SE.  P2
1.2.14 R3 release creation  Creation of the R3 software
release.
1.2.13  3 person-days of SE.
1.2.15 R3 release tests  Testing of the R3 release  1.2.14  12 person-days of SE.
1.2.16 R4 sales release  creation  Creation of the software
sales release
1.2.15  4 person-days of SE.  M3
1.3. Mechanics
1.3.1 Industrial design  Design of the industrial
design for the device.
M1, Must be
started in
parallel with
1.1.1
3 person-weeks of a
ME/industrial
designer.

1.3.2 PCB outline modifications  Modifications of the PCB to
fit the industrial design,
new components and
usability requirements.
1.3.1 2 person-weeks of
ME.

1.3.3 P1 mechanical CAD design   CAD design of mechanical
plastic parts and metal parts
for the device.
1.3.1  1 person-week of ME.
1.3.4 Tolerance stack analysis  Analysis of the mechanical
tolerance stacks compared
to part tooling and
moulding capabilities.
1.3.2, 1.3.3  1 person-week of ME.  M2
1. 3.5 P1 mechanical part analysis  Physical analysis of
moulded plastic parts and
sheet metal parts.
P1 build
complete
1 person-week of ME.
1.3.6 P2 mechanical part
modifications
Modification of moulding
and sheet metal tools used
for P2 parts.
1.3.5 2 person-weeks of
ME.
P2
1.3.7 Mechanical tool approval  Evaluation of P2
mechanical parts and
approval of moulding and
sheet metal tools used in
part manufacture.
P2 build
complete
2 person-weeks of
ME.
M3
1. 4. Verification
1.4.1 Test plan creation  Creation of a plan
documenting what is to be
tested.
M1  1 person-days of TE.  M2
1.4.2 Component tests  Test of key component
reliability to various
standard tests like drop and
humidity.

After delivery
of
components
(for P1)- i.e.
1.5.1 ,1.4.1
12 person-days of TE   P1
1.4.3 Module tests  Test of module
functionality after
assembly.
P1 build
complete,
1.4.2
3 person-days of TE.
1.4.4 System integration tests  Test of integration of
modules.
1.4.3  7 person-days of TE.  P2
1.4.5 Product validation tests  Test of product against
reliability to various
standard tests like drop and
humidity and end user
requirements.
1.4.4, P2 build
complete
12 person-days of TE
1.4.6 Technical Construction File
compilation
Creation of documentation
for regulatory approvals.
1.4.5 10 person-days of
TW.

1.4.7 Type approval and regulatory
approval tests
Approvals from regulatory
authorities.
1.4.6  21 days by regulatory
authorities.
M3

Figure 1 – Activity in Box Network Diagrams for Production

Documentation – Creation
of a user manual
1.7.1
2w  Technical
Writer
M3
M4
P2 component lead-time
1.6.1
4w  Suppliers
1.1.4
P2 PCB manufacture and
delivery
1.6.2
3w  Supplier
P2 mechanical part lead-time
1.6.3
2w  Supplier
P2 assembly and production test
preparation
1.6.4
3w  Production
Engineer
P2
1.3.6
P1 component lead-time
1.5.1
4w  Suppliers
M2
P1 PCB manufacture and
delivery
1.5.2
3w  Supplier
P1 mechanical part lead-time
1.5.3
2w  Supplier
P1 assembly and production test
preparation
1.5.4
3w  Production
Engineer
P1
Hint: Remember that the
R1 software is also
required for the P1
prototype build (1.2.8 in
previous table)
P1 prototype build

1.5.5
4d   P Engineer
P2 prototype build

1.6.5
4d   P Engineer
General Information
In addition to the work breakdown structure and AIB network diagram you have collected the
following information.
  Assume that at the M1 concept review approval will be given to start the project and that the
start date of the project schedule will be  8/9/14. (M1 milestone can be 8/9/14.)
  The project booking of the proto builds (task 1.5.5 and 1.6.5) will have to be done at the latest
two (2) weeks in advance of the build. This is  the lead time required to include builds in the
manufacturing’s master production schedule. There is no need to include the booking on your
schedule initially.
  The company has a general holiday period between 26/12/14 to 2/1/15 and the 6
th
of October
is the designated Labour Day holiday.  For the  purposes of the assignment, assume that there
are no other holidays.
  The booking of the Type Approval (TA) test house (task 1.4.7) has to be done 8 weeks prior
to type approval. There is no need to  include the booking on your schedule initially.
  Production ramp up to manufacture 50 units is estimated to take two (2) weeks after the M3
milestone. Include this task as 1.8 on your schedule above the milestones. It should be the
predecessor for M4.
Available Resources
The maximum full time resources available for your project are:

Resource  $/hour  Number Available
Electronics Engineer  $125.00  1
Software Engineer  $95.00  2
Mechanical Engineer  $125.00  1
Test Engineer  $100.00  1
Production Engineer  $140.00  1
Technical Writer  $75.00  1

All staff work a 40 hour week from Monday to Friday (i.e. a 5 day week with 8 hour days). The
functional managers have assured  you that the engineers are able to do all the tasks within their
engineering field (i.e. there are no differences in the abilities of the 2 software engineers compared to
one another and similarly no difference between the abilities of the 2 mechanical engineers).

If the project is resourced as requested your team is committed to producing only two prototype
iterations to develop and validate the design.

You know that there are items you did not address at the project workshop and that you may need to
make some assumptions to complete your schedule and budget. Make sure that you list any
assumptions you make at the beginning of your assi gnment submission and explain why you believe
your assumptions are valid.
Assessment Part A
For part A of the assessment you must complete the following tasks and questions. Read all the
questions before you commence the tasks. The schedule is to be developed in an appropriately
named Microsoft Project 2010 file (see below) and  the questions are to be answered in a Word
document. As stated above, any assumptions must also be listed at the beginning of the Word
document.

1.   Ms. Marketing has asked you to use Microsoft Project to develop the project schedule. Note
that she has also asked you to include the  milestones at the end of the task list in your
schedule.

Based on the information in the case study description above, use Microsoft Project 2010 to
produce a “Part A” schedule. Make sure that you:
a)   Include the milestones at the end of the task list.
b)   Include the resource allocation details on the schedule.
c)   Have an appropriate project name as the top  of the task list and have all other tasks
indented below this heading.
d)   Make sure that the holidays described in the “general inform ation” are not included in
the available working days for your project.
e)   Use the Microsoft Project software to make sure that the critical path(s) are
automatically highlighted as  red bars  on the Gantt chart view of your schedule.

At this point there may be resource over allocation issues. Do not attempt to resolve these
before answering question 2.  Save this version of your schedule in CQVideoPartA1.mpp.
You will be required to submit this file  as part of your assignment submission.

2.   List the tasks that are on the critical path(s) of the project.

3.   Create a copy of CQVideoPartA1.mpp in another file called CQVideoPartA2.mpp. If there
were any resource over-allocation issues resolve these in this new CQVideoPartA2.mpp file.
Note that you must resolve any resource over-allocation issues without the addition of any
additional resources.  Save the “modified” version  of CQVideoPartA2.mpp. You will also be
required to submit this file as part of your assignment submission.
a)   How did you/would you resolve any resource over-allocation issues without adding
additional resources?
b)   What impact did the resource constraints have on your schedule?

4.   Include additional “milestones” (tasks with 0 duration) in your schedule to show the latest
date when you need to contact:
a)   the production manager to ensure that the  facilities are booked for the first  prototype
build.
b)   the type approval test house to ensure that the facilities are booked for the type
approval.
c)   According to your schedule when is the la test date that you need to contact:
   The production manager to book the facilities for the first prototype build?
   The type approval house to book the facilities for the type approval?
Note that these additional milestones should be listed at the end of the milestones list at the
end of the project task list and should be highlighted in the task list in yellow  using the
“background colour” icon on the task ribbon. This is to allow your marker to locate them
easily.
5.   Write a memo to the director of product development, Mr. Product outlining:
a)   the expected completion date of the project, assuming it commences at M1 (8/9/14);
b)   the total duration of the project;
c)   an explanation of the main factors that cause the project to require that length of time;
d)   the estimated labour cost of the project af ter the M1 concept review. Present the costs
in a table showing the costs for the following:

   Electronics
   Software
   Mechanics
   Verification
   Prototype 1 build
   Prototype 2 build
   Documentation
   Production ramp up to 50 in stock
   Total for the Project

Assume that you will send the project sch edule as an attachment to the memo.

6.   What should the project manager do to manage risk in this project? Provide examples of your
solution. (maximum 500 words)

7.   Is there any way that the overall budget of the project can be reduced without removing any
tasks? (Justify your answer. Be specific and descr ibe any tasks that you would target and what
you might do that could reduce the cost of the project.) (maximum 500 words)

8.   Describe what the project manager needs to do to ensure that the project runs smoothly and
completes on time. Give a detailed answer describing procedures, processes and anything else
that you believe is important both in general terms and specifically for this project. (maximum
500 words)

9.   Are there any other project related supporting activities, plans, events or tasks that you might
have overlooked?  If they were overlooked descr ibe how this could impact on the project.
(Aim to identify and discuss at least two activities.) (maximum 500 words)

10.  What should the project manager do to ensure product quality? (maximum 500 words)

Assessment Part B

Mr. Production reviews your project schedule and requests that build participation of one engineer
from each of the following functions is required at the  P1 and P2 builds : production, electronics,
software and mechanics. These additional resources w ill not change the task durations. You will have
to update your schedule as you agree with this proposal.

You are now 1 week after the M1 milestone and the Chinese mechanical servo  supplier for task 1.5.3
has had to revise the delivery time. The delivery time has now greatly increased to 7 weeks,  which is
longer than the time required for the  other components in the P1 build.

In addition the mechanical engineer has completed  the mechanical specification. However, this has
meant that the estimated time for the “P1 mechanical part analysis ” has had to be revised. This task
is now estimated to require an extra week .
Based on the additional information given above complete the following tasks:

1.   Create a copy of CQVideoPartA2.mpp in another file called CQVideoPartB.mpp. Amend the
project schedule in CQVideoPartB.mpp incorporating the request from Mr. Production, the
change to the delivery time for the servo and the  new estimated times for the software tasks.
If necessary resolve any resource over-allocation issues without adding any resources. You
will also be required to submit this file (C QVideoPartB.mpp ) as part of your assignment
submission.

2.    Describe the impact(s) of each the following on the project  schedule :
a.   The additional resources required for the prototype builds.
b.   The change in duration of the delivery time for the servo component.
c.   The change in time for the P1 mechanical part analysis.
Explain your answers.

3.   Describe the impact(s) of each the following on the  project  budget :
a.   The additional resources required for the prototype builds.
b.   The change in duration of the delivery time for the servo component.
c.   The change in time for the P1 mechanical part analysis.
Explain your answers.

4.   Project changes can influence the schedule and budget of successor tasks in a project and this
can also have a large impact on other project stakeholders. What steps could the project
manager take to allow a smoother transition of project changes? Provide  two  specific
suggestions in your answer.

Assumptions
You are free to make any assumptions necessary to complete the assignment. However, each
assumption must be justified and stated clearly in your assessment Word document. Marks will be
deducted for any unreasonable assumption or for stating an assumption and then ignoring it in your
assignment.
Submission of Assessment
The assignment is to be submitted as four separate files using the electronic assignment submission
system that can be accessed from the assessment item 2 link on the course website. The four files to
be submitted are:

1.   The Word document with the assumptions and solu tions to the questions for Part A and Part
B.
2.   The Microsoft project files created for Part A and Part B. Please ensure that the Microsoft
Project files are named according to the instructions in the assignment specification
(CQVideoPartA1.mpp, CQVideoPartA 2.mpp and CQVideoPartB.mpp).

Marking Guide for Assessment item 2 – Individual Case Study
Assignment Question  Criteria  Marks
available
Marks
awarded
Part A
Q1  The adequacy of the Project Schedule
  Tasks; correct WBS; overall summary task;
auto scheduling
  Durations/effort
  Resources allocated
  Milestones
  Predecessor relationships
  Holidays
  Critical path highlighted
(may have resource over allocation at this point)
7
Q2  Critical path tasks listed   1
Q3  (a), (b) – dealing with resource constraints  2
Q4  Dates of bookings (+ milestones)  1
Q5  Appropriateness of the Written Memo and all
information included and correct according to the
schedule
4
Q6  How to manage project risk  3
Q7  Details on reducing the project budget  3
Q8  Ensuring finished on time  3
Q9   Overlooked “activities”   2
Q10  How to ensure a quality product  3
Sub Total Part A    29
Part B
Q1  The adequacy of the amended Project Plan (+
ensure no resource over-allocation)
2
Q2  Discussion of the impact of each of the changes on
schedule + explain
1.5
Q3  Discussion of the impact of each of the changes on
budget + explain
1.5
Q4 Change management  1
Sub Total Part B    6
TOTAL   35

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