Overcoming the 90% Syndrome: Iteration Management in Concurrent Development Projects

Successfully implementing concurrent development to reduce cycle time has proven difficult due to unanticipated iterations. We develop a dynamic project model that explicitly models these interactions to investigate the causes of the “90% syndrome,” a common form of schedule failure in concurrent development. We find that increasing concurrence and common managerial responses to schedule pressure aggravate the syndrome and degrade schedule performance and project quality. We show how understanding of and policies to avoid the 90% syndrome require integration of the technical attributes of the project, the flows of information among participants, and the behavioral decision-making heuristics participants use to respond to unanticipated problems and perturbations.

[1]  O. Hauptman,et al.  The influence of process concurrency on project outcomes in product development: an empirical study of cross-functional teams , 1996 .

[2]  Tom DeMarco,et al.  Controlling Software Projects , 1982 .

[3]  P. C. Nutt How Decision Makers Evaluate Alternatives and the Influence of Complexity , 1998 .

[4]  Viswanathan V Krishnan,et al.  Managing the simultaneous execution of coupled phases in concurrent product development , 1996 .

[5]  David N. Ford,et al.  The Liar's Club: Concealing Rework in Concurrent Development , 2003, Concurr. Eng. Res. Appl..

[6]  K. L. Edwards Concurrent engineering: What's working where , 1996 .

[7]  Herbert A. Simon,et al.  The Sciences of the Artificial , 1970 .

[8]  Christoph H. Loch,et al.  Communication and Uncertainty in Concurrent Engineering , 1998 .

[9]  Daniel Roos,et al.  The machine that changed the world : the story of lean production , 1991 .

[10]  Art Kleiner,et al.  The learning initiative at the AutoCo Epsilon Program : 1991-1994 , 1997 .

[11]  H. Thomas Effects of scheduled overtime on labor productivity , 1992 .

[12]  Dietrich Dörner,et al.  The Logic Of Failure: Recognizing And Avoiding Error In Complex Situations , 1997 .

[13]  Fran Ackermann,et al.  The Effects of Design Changes and Delays on Project Costs , 1995 .

[14]  Milton D. Rosenau,et al.  Fast cycle time: How to align purpose, strategy, and structure for speed: by Christopher Meyer, Ph.D. New York: The Free Press, 1993. 290 + xiii pages. $29.95 , 1994 .

[15]  Robert P. Smith,et al.  A predictive model of sequential iteration in engineering design , 1997 .

[16]  Durward K. Sobek,et al.  The Second Toyota Paradox: How Delaying Decisions Can Make Better Cars Faster , 1995 .

[17]  David N. Ford,et al.  Dynamic modeling of product development processes , 1998 .

[18]  Albert M. Bottoms,et al.  Made in America: Regaining the Productive Edge , 1990 .

[19]  Nelson P. Repenning,et al.  Getting quality the old-fashioned way : self confirming attributions in the dynamics of process improvement , 1997 .

[20]  Steven D. Eppinger,et al.  Performance of Coupled Product Development Activities with a Deadline , 2001, Manag. Sci..

[21]  Paul J. Componation,et al.  Prioritizing components of concurrent engineering programs to support new product development , 1999 .

[22]  Steven C. Wheelwright,et al.  Revolutionizing Product Development: Quantum Leaps in Speed, Efficiency and Quality , 1992 .

[23]  F. A Maxam Design Development of the 727-100 , 1978 .

[24]  Linda Moffat,et al.  Tools and teams: competing models of integrated product development project performance , 1998 .

[25]  K. Clark,et al.  Dynamic Manufacturing: Creating the Learning Organization , 1988 .

[26]  Tyson R. Browning,et al.  Sources of Schedule Risk in Complex System Development , 1999 .

[27]  Daniel E. Whitney,et al.  Concurrent Design of Products and Processes: A Strategy for the Next Generation in Manufacturing , 1989 .

[28]  Paul S. Adler,et al.  From project to process management: an empirically-based framework for analyzing product development time , 1995 .

[29]  Stuart E. Madnick,et al.  Software Project Dynamics: An Integrated Approach , 1991 .

[30]  Robert P. Smith,et al.  A model-based method for organizing tasks in product development , 1994 .

[31]  Robert P. Smith,et al.  Product development process modeling , 1999 .

[32]  P. Libby The Scientific American , 1881, Nature.

[33]  C. J. Haddad Operationalizing the concept of concurrent engineering: a case study from the US auto industry , 1996 .

[34]  Christoph H. Loch,et al.  Accelerating the process of engineering change orders: capacity and congestion effects , 1999 .

[35]  Christoph H. Loch,et al.  Exchanging Preliminary Information in Concurrent Engineering: Alternative Coordination Strategies , 2002, Organ. Sci..

[36]  Erik Jan Hultink,et al.  4 Product development performance: strategy, organization and management in the world auto industry☆ , 1994 .

[37]  G. Klein,et al.  A recognition-primed decision (RPD) model of rapid decision making. , 1993 .

[38]  J. Sterman Learning in and about complex systems , 1994 .

[39]  David N. Ford,et al.  Expert knowledge elicitation to improve formal and mental models , 1998 .

[40]  Laura Rountree Smith January , 1890, The Hospital.

[41]  Eliyahu M. Goldratt,et al.  The theory of constraints and its implications for management accounting , 1995 .

[42]  John D. Sterman,et al.  System Dynamics: Systems Thinking and Modeling for a Complex World , 2002 .

[43]  C. Terwiesch,et al.  Managing the Process of Engineering Change Orders: The Case of the Climate Control System in Automobile Development , 1999 .

[44]  M. L. Patterson,et al.  Accelerating Innovation: Improving the Process of Product Development , 1992 .

[45]  Steven D. Eppinger,et al.  A Model-Based Framework to Overlap Product Development Activities , 1997 .

[46]  Michael Burda,et al.  Revolutionizing product development , 1993 .

[47]  G. Klein,et al.  Decision Making in Action: Models and Methods , 1993 .

[48]  Steffen Bayer,et al.  Business dynamics: Systems thinking and modeling for a complex world , 2004 .

[49]  M. D. Wilkinson,et al.  Management science , 1989, British Dental Journal.

[50]  Parag A. Pathak,et al.  Massachusetts Institute of Technology , 1964, Nature.

[51]  T. Petersen,et al.  Systems engineering as applied to the Boeing 777 , 1992 .

[52]  J. Ettlie Product-process development integration in manufacturing , 1995 .

[53]  David N Ford The dynamics of project management : an investigation of the impacts of projects process and coordination on performance , 1995 .

[54]  Fred P. Brooks,et al.  The Mythical Man-Month , 1975, Reliable Software.

[55]  Ann Majchrzak,et al.  Concurrent engineering tools: are the human issues being ignored? , 1996 .

[56]  B. J. Zirger,et al.  The effect of acceleration techniques on product development time , 1996 .

[57]  Kenneth Cooper Naval Ship Production: A Claim Settled and a Framework Built , 1980 .

[58]  Tarek K. Abdel-Hamid,et al.  Understanding the "90% syndrome" in software project management: A simulation-based case study , 1988, J. Syst. Softw..

[59]  Milton D. Rosenau Book review - Effective Product design and development: How to Cut Lead Time and Increase Customer Satisfaction, Stephen R. Rosenthal. BusinessOne Irwin, Homewood, IL (1992), 341+xxiv pages. $42.50 , 1992 .