1 Introduction

Traditional Project
2 Management

Traditional Project
3 Management

Project Management
4 Process Models

Automotive PLC
5 Introduction to Agile

Project Management
LESSON 5 – AUTOMOTIVE PLC
INTRODUCTION TO AGILE

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 Automotive PLC (exemplary)

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 Automotive PLC – Sample Phases
Sample Goals Description Annotation
Phase
A-Sample Proof of feasibility The A sample fulfills the basic functionality. There may be The A sample is often the predecessor model
deviations in performance, functional scope as well as geometry on which the adaptation is based, extended
and mass. The sample may be made from prototype materials and by the variance analysis.
with prototype tools and processes. Basic software functions are
available.
B-Sample Design Validation The B sample fulfills the full functionality in the target package.
Series materials are used. The sample may have been produced
with prototype tools and processes. All software functions are
available, and an initial parameterization has been completed.
C-Sample Production Process The C sample fulfills the full functionality in the target package.
Validation Series materials and series tools are used. The sample may be
built with prototypical manufacturing process. All software
Safety Validation functions are available, the parameterization is complete, and the
safety functions are fully validated.
D-Sample Product Validation The D sample fulfills the full functionality in the target package. The quality, depth and scope of series
Series materials, series tools and the series manufacturing material, series tooling and in particular
process are used. The series software is released. series manufacturing process depends on
the number of units and the business case
and must be planned in the project tailoring.

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 Automotive PLC (exemplary)

Gate Name Description Responsible Main Artifacts

G10 Opportunity All stakeholder requirements are available in the form of a (Product) Project Order for Definition
Approved specification sheet and the business opportunity in the Management Phase
form of the business plan is presented.
Requirements level 0
(Client/Stakeholder)
G15 Concept All technical requirements have been analyzed in the form Project Manager Requirements lvl 1-2
Approved of a specification sheet and the resulting risks of the (system/sub-system)
project are known. The high-level project plan is valid and
complete. Risk Assessment
G20 Project Planned The costs and risks of the project are known and Project Manager Schedule
calculated. The project plan is valid and complete.
The business case is reassessed with these numbers
G30 Development The customer order is available in the form of the project Project Manager Resource Plan
Start order. The complete team is nominated, informed and the
project infrastructure is established.

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 Automotive PLC (exemplary)

Gate Name Description Responsible Main Artifacts

G40 Design Defined Goal is the first iteration of the validation of the (Technical) Project Test Reports
requirements of the specifications. The result is the first Manager
available and tested physical sample and a test report to
verify the requirements or identify deviations.
G45 Design Stable The development phase has reached the design freeze. (Technical) Project Sample BOM
After this milestone, changes to the sample need to Manager
undergo the defined change management process.
G50 Design Goal is to validate all requirements of the specifications. Project Manager Series BOM
Validated The result is the release of materials and tools for series
production and a test report to confirm the requirements or
identify deviations.

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 Automotive PLC (exemplary)

Gate Name Description Responsible Main Artifacts

G60 Production Goal is to verify the planned production process through (Technical) Project Production Process Plan
Process build-up of a sample. While the product is released for Manager
Defined series production and unchanged, the production line here
is in prototype/sample status.
G70 Product The product built on the final production line passes all Project Manager Series Release
Validated verification & validation processes and is released to series
production.
G80 Launch The series production is running on full scale without Project Manager
Completed deviations.

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 Automotive PLC (exemplary)

Gate Name Description Responsible Main Artifacts

G90 End of The production is finished. Only stock goods are sold off. Management
Production
G100 End of Life The warranty period for the last products sold has ended. Aftersales
The product support is coming to an end.
G110 Obligation Any remaining obligations, such as recycling of returning Aftersales + Legal
Ended goods have ended.

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 Automotive PLC – Sample Development
SYS M1: Activities Planned
Activities planned in System Engineering.
▪ Functional Safety Plan
▪ System Test Plan (definition of e.g. test specification; test
bench / test site, ... )
▪ Cybersecurity Plan
▪ Planning on system engineering level.
▪ Feedback of the four plans to project management &
commitment to this plan.

SYS M2: SYS Defined

System architecture defined. Requirements are broken
down to disciplines.
▪ System Architecture
▪ Requirements Lvl. 2 & 3 (discipline / component) defined

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 Automotive PLC – Sample Development
ME, E/E, SW M1: Requirements Freeze
Specifications book at discipline level fully reviewed and
released.
▪ Requirements level 4 (parts) defined.
▪ Start of change management for requirements

ME, E/E, SW M2: Activities Planned

Activities planned by ME, E/E and SW based on system
architecture and specific requirements.
▪ Planned activities on disciplines level
▪ Feedback of plans to project management &
commitment to this plan.

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 Automotive PLC – Sample Development
ME, E-E M3: Design Freeze
Design is completed. Drawings at technical level agreed
with suppliers.
▪ BOM
▪ Drawings
▪ CAD model
▪ (Initial) assembly instructions
▪ Start change management for design

PUR M3: All Components ordered

All components of the BOM are ordered.
▪ BOM updated by feature "ordered

PUR M4: All Orders confirmed

All orders have a confirmation of receipt and all delivery
dates are fixed.
▪ BOM updated by characteristics "confirmation of receipt" and
"delivery date".

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 Automotive PLC – Sample Development
PS M3: All Components delivered
All components have arrived.
▪ BOM updated by characteristics "Goods received

ME, E-E, M4: all components checked / tested

Goods receipt inspection performed and component tests
completed if required.
▪ BOM updated with characteristics "goods ok".

PS M4: Prototype store prepared

Assembly stations and tools are prepared, assembly
instructions are available. Necessary supplies such as test
software, measuring equipment, etc. are available.
▪ All assembly stations ready (tools, standard parts, etc.
available, components prepared for shoring).
▪ Assembly instructions complete and understood
▪ Provisions are available
▪ Assembly planning completed & committed

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 Automotive PLC – Sample Development
PS M5: Sample available
Physical sample is ready for assembly
▪ Physical sample
▪ Setup check completed (torques, distances, bending
radii, ...)
▪ Operating material completely filled.

SYS M5: Sample available

Preparation for commissioning and system tests is
completed.
▪ System test specification defined
▪ Test setup / site available

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 Automotive PLC – Sample Development
ME, E/E, SW, SYS M5: Test preparation
Sample is prepared for testing
▪ Physical sample is prepared with sensors
▪ Test labs are prepared and scheduled
▪ Test sets are finalized and scheduled
▪ Commissioning of the test sample

ME, E/E, SW M6: Specific Tests

The sample is tested according to the disciplines testing
requirements.
▪ Testing of single components
▪ Testing of sub-systems
▪ Verification ME, E/E, SW development results

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 Automotive PLC – Sample Development
SYS M6: System Test
Preparation for commissioning and system tests is
completed.
▪ System test specification defined
▪ Test setup / site available

SYS M6: Sample release

Sample is commissioned and system tests have been
performed.
▪ Sample is released (Release Test Protocol; Release
Notes).
▪ All previous milestones are achieved.

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 Traditional, agile and hybrid project management
The pressure for efficiency to compete in global
markets, especially with goods manufactured through
labor intensive production kicked-off the introduction of
project management methods to monitor any deviations
and optimize the development and especially the
production.
With more and more saturated global markets
differentiation through innovative products of increasing
complexity and a shift from costs from production to
development, a need for controlling projects without
stifling needed innovation and team interaction.

1) Wohland et al. 2004; Pflaeging et al. 2015; Kuster et al. 2019, p. 30

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 Agile

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 Traditional
Focus on Quality / Scope / Output
▪ Safety (Processes against “laziness” &
documentation)
▪ Quality of documentation
▪ Hard project handover milestones (purchasing,
production, etc…)
▪ Faulty or wrong Hardware is connected to high costs
▪ Fixed set of features for an optimized price
▪ Untrained / low qualified personell
▪ Simplification of development and production steps
▪ Repetitive development

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 Agile
▪ Quick innovation cycles
▪ Fast reaction to market demands and changes
▪ Complex and changing requirements that do not
allow for valid planning
▪ Small Steps or Small Phases (Features)
▪ Low availability of components (first purchaser
comes first)
▪ Innovative showcase projects especially in smaller
companies (necessary cost control) – full feature set
is secondary
▪ Motivated and capable teams

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 Agile Manifesto

Individuals and interactions over processes and tools

Working software over comprehensive documentation

Customer collaboration over contract negotiation

Responding to change over following a plan

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