Managing Change in the Delivery of Complex Projects
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This research analyzes practices of managing change in complex projects, focusing on configuration management, asset information, and 'big data'. It examines leading practices in Airbus, CERN, and Crossrail, discussing the challenges of managing change in the era of 'big data' and implications for research and practice.
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railways.Their delivery requires systems integration capabili- ties,as complex productsystems are designed and integrated through a network ofcomponentand sub-system suppliers (Davies and Mackenzie,2014; Davies et al.,2009; Hobday et al.,2005).Within these projects information aboutcomplex product systems is developed across multiplefirms,involving diverse professions and trades,as these organizations interact through the digital systems. A starting point for our work is the observation that, as we enteran era of‘big data’,assetinformation is becoming a projectdeliverable.Dataare unprocessed,often described as “unorganized facts”(e.g.Faucheretal.,2008:p.55),while informationis interpreted and presented to inform in a given context.Ownersseek to useassetinformation to achieve sustainable and safe performance of complex systems through the life-cycle. An asset may be an assembly, sub-assembly, or component,butis the smallestunitmaintained by an owner. The term‘assetinformation’is used to describe information aboutan asset,which may include the provenance,parttypes and serialnumbers,design life,maintenance schedule,and design rationale for sub-systems or components.As data gets reused acrossthelife-cycle,setsofdataand information become combined and can be mined,interpreted and used in new ways. The UK government, for example, is, as a client for builtinfrastructure,requiring projectteamsto deliverasset informationthroughbuildinginformationmodelling(BIS/ Industry Working Group,2011);and seeks to aggregate and combine data-sets, connecting them with Smart City and Smart Grid initiatives as partof a strategy for DigitalBuiltBritain (UK Government, 2013). Established approaches for managing change on projects use configuration management, a systems engineering approach with origins in the mid-20th century. In its original form, configuration management is characteristics of whatLevitt (2011)describes as ‘project management 1.0.’It involves hierarchical, sequential and asynchronous processes; managing change against a baseline. Its usefocusesattentiononassetsasconfigurationitems: sub-systems or components that have value to the organization, in which changes will often have systemic consequences on the function or layout of other items within the product structure and hierarchy.The baseline is an agreed description ofone ora numberofassetsatapointintime,wherethecurrent configuration of a complex product system is described by the latest baselines plus approved changes. New practices of managing change in complex projects m be expected as we enter an era of‘big data’, in which inter external data-sets become linked and asset information be project deliverable. Morris argued that:“rigorous change co is fundamentalto good projectmanagement”(Morris,2013: p.126).Poorchange controlis one ofthe issues thatlimits managers’ability to execute viable project plans (Pinto,2013). Othersseeprojects,themselves,asinformationprocessing systems(e.g.Winch(2010)drawingonGalbraith(1973, 1977)).As projectmanagementinformation systems (Braglia and Frosolini, 2014) are increasingly used, altering the pac complexity (Shenharand Dvir,2007)ofprojects,there are challenges to the:“heavy formality of several of the techni to manage large-scale, one-time, non-routine projects”(Mo 2013:p.133).Here,Morris,like Levitt,pointsto software projects, in particular, as rebelling, using agile forms of ma ment,through smallprojectswith close developer-customer relationships. The aim ofthis research is to articulate how changes in assets and the associated asset information are managed i delivery of complex projects as we enter the era of‘big dat This is done by analysing leading practices in three organiz tions: Airbus, CERN and Crossrail. Each of these organizatio deliverscomplex projects;relieson digitaltechnologiesto manage a large volume of information; and uses configura managementto establish and maintain the integrity ofthe complexproductsystem andassociatedinformation(see Table 1).Airbus is an aircraftmanufacturer,operating in the aerospace industry and engaged in production of commerc and military aircrafts,with long-term projects to design and develop new aircraft designs and bring them into operation headquarters are in France but the supply-chain is global, w the assembly of each plane involving thousands of compan and millions of parts.CERN is the European organization for nuclearresearch and thelargestparticlephysicsresearch establishment in the world, with 21 member states, 6 obse states and more than 80 collaborating countries. Its missio provide scientists from all around the world with tools to st the building blocks of matter and the origins of the univers Crossrailis the largestconstruction projectin Europe,with 14.8bn funding,delivering a new 100 km railroute with 10 new stations and a tunnelthrough centralLondon connecting 40 stations. It has a complex supply-chain involved in deliv with more than 1,300 contracts. Table 1 Background of organizations studied, and their industries. AirbusCERNCrossrail IndustryAerospace design and manufacturingNuclear research infrastructureCivil engineering and railway infrastructure BackgroundLeading aircraft manufacturer of commercial and military aircrafts, with a substantial international supply-chain. Largest particle physics research establishment in the world with tunnels and particle accelerators Design and construction of new railway across London with tunnels and 37 stations Relationship to projectsLong term internalprojectsto design and manufacture new additions to thefleet, such astheA380,integrating sub-systemsand components and delivering to customers. Experienced project owner, managing supply-chain delivering accelerators such as the Large Hadron Collider (LHC) Delivery client for a mega-project, the duration of which is 2008–2018, interfacing with future operators of the railway. LocationFranceSwitzerlandUK 340J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
Thenextsection outlinesextantresearch on managing change in delivery,before the following sections describe our research methods andfindings.It outlines the development of configuration management techniques; characteristics of an era of big data;and relevance configuration managementand big data to Morris’interest in‘reconstructing project management.’ 2. Managing Change in Project Delivery 2.1.Developmentofconfiguration managementtechniques to manage change Configuration management was developed in the 1950s by the US military to control documentation in the manufacture of missiles (Brouse, 2008; Burgess et al., 2005; Gonzalez, 2002). Early documentation on engineering change control,released by the military,clarifies the contractualobligations and role ofsuppliers.Itrefersto a productbaseline describing the functional,physicalandinteroperabilitycharacteristicsof components for testing and operations (DOD,1978;Military, 1988). Two example change processes, used in the commercial arrangements ofacquisition and supply,are provided by the Department of Defense guidance issued in 2013 (seeFig. 1for one of these,where the other is a variant).As well as change control,theclassicapproach to configuration management involves the identification ofthe productstructure and con- figuration items; status accountingto determine the configura- tion of the system at any stage of the lifecycle (Burgess et al., 2003;Kidd and Burgess,2010) and reporton the availability and retrievability of data; andauditto verify the consistency of the information (Kidd and Burgess,2010).The approach has become extensively used in the software industry (Bersoff, 1984;Estublier,2000;Williams,2009),and in safety critical systems such as nuclear and aerospace (Burgess etal.,2005; Williams, 2009). It became recognized as an ISO 10007 quality managementprocess in 1995 (ISO,2003).The presentation, with a man ata drawing board,shows the heritage ofthis approach in the paper-based processes of the late 20th century; though in the 21stcentury such processes are supported by digital systems. TheUS militarydescribesconfigurationmanagement’s overarching goalas:“to ensure there is documentation which completely and accurately describes the intended designthe actualproductmatchesthedocumentation,and thereare processes in place so this continues throughoutthe product’s life”(DOD,2013:p.10).Theambition isto addressthe problems which occur in projects due to unchecked chan one sub-system having widerconsequencesforothersub- systems of a product (Hameri,1997); and due to scope creep, where requirementschangeduring the processofdelivery (Williams,2009);providing traceability ofproductdata to understand where problems occur, diagnosing and contri to recovery (Burgessetal.,2003).A configuration is:“a generic term for anything thathas a defined structure or is composed of some predetermined pattern”(Kidd and Bu 2010:p.109).An authorization approach is used to control change and there are differenthierarchy levels depending on the use of configuration items (Billingham, 2008). A base established:“wherever it is necessary in the product life to define a reference for further activities.”(ISO,2003: p.4). From an approved baseline,a configuration change authority assessestherecommendationofotherrepresentativesto approve,approve with modifications,or disapprove submitted changes based on the:“totallifecycle impactofthe action to includecost,schedule,performanceand logisticsimpact” (DOD,2013:p.27).Thus the processes,procedures and users of the configuration managementsystem play an integral role in maintaining theintegrity ofinformation throughoutthe life-cycle by controlling changes.Ifusers do notfollow the process,errors can occurwhich can cause problems to the product in production and to related information dissemin (Hameri,1997;Hameriand Nitter,2002).Researchersof configuration management constantlyfind the benefits o a controlled process of change are notalways understood or realized by users (Aliand Kidd,2014;Burgess etal.,2003; Kidd, 2001; Kidd and Burgess, 2010). The upsurge in the use of digitaltechnologies andflexible team-working bring into question configuration managem practices based on documents rather than information (B et al., 2005). Characteristics of‘configuration manageme Submission of: •Engineering change proposal (ECP) for asset •Notice of revision (NOR) to associated information Configuration Control Board New revision released Configuration change authority approval Draft change Engineering release record (ERR) process Original document Configuration officially accepted ECP NOR ERRREV BREV C 123123 Fig. 1. Standard change process (redrawn from source:DOD, 2013: p. 33, to clarify and explain acronyms, same images of documents a 341J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
notstable andfixed butare themselves evolving,to include the life-cycle, agile approaches, and changes to strategy as well asproject.Forexample,aftercancelling itsconfiguration management standard MIL-STD-973 in 2000,the US Depart- mentofDefensefoundthatitcontinuedtobeusedin non-standard ways. From 2010 they developed a new standard forconfiguration managementto changes through life using digitalsystems(Windham,2012).Theinterim standard mentionsthree baselines,with a functionalbaseline giving system level requirements; allocated baseline giving subsystem or configuration item level requirements; and product baseline giving detailed definition (DOD, 2013: p. 18). There are recent attempts to develop an agile approach to configuration manage- mentthrough asystem to accommodatesmallcontinuous changes and manage the additional complexity across dispersed teams (Moreira,2010);and reports suggesting an expanded scope ofconfiguration management,to include enterprise as well as product baselines (Wozny et al., 2014). 2.2.Reuse of information and data linkages in the era of‘big data’ There are rapid developments in digital technologies and an extensive growth in the volume ofdata stored digitally that affects projectdelivery.The term‘big data’indicates the use oflargeheterogeneousdata-setsthatcanthemselvesbe aggregated,and subjected to variousformsofanalyticsto enable patterns in the data to be visualized.While there is not agreementon a precise definition,many writers,across both information science and socialscience literatures,draw on Laney (2001)to referto data volume,velocity and variety. Volumeof data is implied by the term‘big data’and is an issue because there is an increasing extent of data available (Wu and Wu, 2014), with 2.5 exabytes of data created globally each day in 2012 and expectations thatthe rate of data production will double every 40 months (McAfee and Brynjolfsson, 2012: 62). Yet recentwork emphasises characteristics other than volume (Boyd and Crawford, 2012; Kitchin, 2014).Velocityrelates to the speed ofproduction and ofaccess ofdata.Advances in computing processing capacity enable data-sets to be engaged with in real-time, or near real-time, rather than‘freeze framed’ (Kitchin,2014)orprocessed offline.Varietyrefersto the diverserangeofdatasourcesand typesofdatathatare combined (Viitanen and Kingston,2013; Wu and Wu,2014). On projects this variety can include hierarchically structured data such as models, and unstructured data such as laser scans, videos,sensordata,photosand experimentaldata.While volume, velocity and variety are generally characteristic of the applications described as‘big data’,these applications vary in the extentto which they emphasise one or the other of these characteristics. Big data represents a paradigm shift,where“mostofour attitudes and behaviours still reflect hierarchical and sequen- tialprocessing ofdata”(Galbraith,2014).Information is no longer created and used for a single purpose (Constantiou and Kallinikos, 2015). As we enter an era of‘big data’, information from projects becomes seen as a projectdeliverable and used throughoutthe lifecycle.Organization scholars observe how: “organizations are swimming in an expanding sea of data t is either too voluminous or too unstructured to be managed analyzed through traditionalmeans”(Davenportetal.,2012: p.22).Differentprofessionalusers bring theirown way of organizing data to understanding it, so early work highlight needforindexingstrategiesthatwereagnostictothese structures (Laney,2001: p.1).Big data is different from‘lots of data’as itis:“those data thatdisruptfundamentalnotions ofintegrity and force new waysofthinking and doing to reestablish it”(Lagoze, 2014: p.4-5). It thus raises a conund for science (Lagoze,2014): how to utilize the benefits of‘big data’while maintaining the validity of data. Despite ongoing concerns aboutintegrity,many organiza- tionsaremovingawayfrom asynchronousandreactive decision-making;totheuseofpredictiveanalyticsfor real-timeand proactivedecision-making.Within thesocial science literatures on‘big data’,analytics is described as a differentiatoroforganizationalperformance (LaValle etal., 2011);a source of competitive advantage (Barton and Court 2012;McAfee and Brynjolfsson,2012);ornew frontierof competition (Floridi, 2012). Here, the challenge of big data been reframed as one ofidentifying smallpatterns (Floridi, 2012) within immense databases, and the use of these to c new value and knowledge.Emerging technologies are associ- ated with this business analytics (Chen etal.,2012);and the way that information is considered is different, as analytics be used to seek insights from theflow of information as we its content (Williams et al., 2014). Various text and web mi as wellas socialnetwork analysis techniques are becoming used to organizeand visualizeinformation to understand performance in organizations (Chen etal.,2012;Williams et al., 2014). The many-to-many non-linear data relationships arise in large and evolving data-sets (Wu and Wu, 2014) le challenges in ensuring reliability,which has implications for decision making.Differentpreferences in recording data can resultin diverse representations and relationships thatmakes itdifficultto discoverusefulpatterns (Wu and Wu,2014). Synthesized information may thusneed to be situated in a broaderhistoricalcontextto be used in a predictive manner (Boyd and Crawford, 2011). The power offlexibly linking assetinformation with other data-sets is beginning to be realized by owners ofcomplex productsystems such as infrastructure.Transportfor London has, for example, made data available to customers, and a engineers,to combinedatain new waysto develop new applications.1Williams et al. (2014)point to the potential for a census ratherthan sampling approach to organizationaldata to be used to assessorganizationalmaturity in the use of project-management. Recent industry reports envision a fu in which data-sets are linked and analytics are used predict ly,forexampletoprecomputescenariosandinform decision-making (e.g.BIM 2050 Group,2014).There may be latent applications in complex projects, for example in the 1Seehttps://www.tfl.gov.uk/info-for/open-data-users/(Anotherexample is http://data.london.gov.uk/). 342J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
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ofdashboards as an interface to whole data-sets to evaluate supply-chain performance. 2.3.‘Reconstructing’project management: configuration management in an era of big data Morris(2013)hasan ambition to‘reconstruct’project managementbyshiftingattentionfrom theexecutionof projects to the managementof projects–which includes the definition of the project, the role of the owner or sponsor, and the project context. This wider view is necessary to investigate how change is managed in an era of‘big data’where asset information has becomes a projectdeliverable.The complex projectdelivers an assetthatis used in operations.As asset information becomes a deliverable,Fig. 2shows how data-sets become increasingly aggregated and linked in the delivery of the project,with links to externalsources ofdata (e.g.from suppliers,manufacturersand maintainers),and the complex projectresponsibleformanaging changein an increasing volume, velocity and variety of data in project digital systems. Thisanticipatespotentialnew connections,forexample between information used in the project and reference schedule and cost data; and between asset information and the owner’s enterprise resource planning system. Digitalsystemsare nothomogeneous,butcombine net- works,servers,and computerswith softwarefordifferent purposes,and from differentvendors.They are used in the storage,retrieval,management and manipulation of data; with data management software used to upload, integrate, structure, index and search data,and to manage remote access, security, versions and workflows. Stored data includesfiles, folders and meta-data;held in a range ofspecialistsoftware.In projects most of this data is classified and structured,though it can be combined with a variety ofsources ofunstructured data in projects,which havepreviously been ignored (Boyd and Crawford,2011).Where organized fora particularpurpose we describe itas information,hence assetinformation as a deliverable is managed digitally, and reuses the same data-sets that have been used to inform decision-making in delivery. A major question,raised by the era of‘big data’relates to control and the management of change as digital data-sets cross organizationalboundaries;particularly asinformation about assetsgetsre-usedinoperations.Inmanufacturingand construction industriestheuseofinformation through the life-cycle is often referred to as Product Life-cycle Manag (PLM) and Building Information Modeling (BIM) respective The practical concerns of project managers about contro contextare reflected in the reportofa meeting ofthe Major Projects Association,which in summary notes that:“Manual uploading of data between software programmes allows understanding of progress and visibility”(MPA, 2013: p. 3 this report there are concerns that project managers feel as the project controls themselves produce massive data solutionsproposed are manualinterventions,to identify key information or manually transfer data. Configuration management is discussed little in the pro management literatures,and where it is mentioned,notably in Morris’work, it is as implemented through the digital sys used on projects. In the move toward the“era of the pap project”, Morris describes configuration management:“e ed to include the configuration ofthe totalprojectdocumen- tation handling process.”(Morris,1997:preface,note4); noting increasing focus on information rather than docum The Project Management Body of Knowledge Guide likew refers to the configuration management system as a com oftheprojectmanagementinformation system,containing versionsand baselinesforallprojectdocuments(PMBOK guide,2013:p.28).Standards for asset managementlikewise indicate this need to manage changes to assets assessin and consequences of change.While we know that users resist configuration managementprocesses and these are notfully implemented (e.g.Aliand Kidd,2014),we know little about how change is managed on complex projects, as we mov an era of‘big data,and assetinformation becomes used as a project deliverable. We approached our empirical work w question about how changes in assets and asset informa managed in this context as summarised inFig. 2. 3. Methods Usingacasestudymethodology(e.g.Eisenhardtand Graebner, 2007; Stake, 1995; Yin, 1994), we analysed ch managementpractices in the three separate organizations a cases,and then compared and contrasted thefindings acr casestodevelopfurtherinsight.Theorganizationswere selected as leading organizations that deliver complex pr systems using digital technologies to manage the large v of associated information.Data was collected from the three organizations,andtheirinteractionswitheachotheras summarized inTable 2.Ourinitialcontactwith participants indicated ourinterestin examining thetransition from an “as-designed”configuration baseline to an“as-built”con ration baseline;as information was delivered to owners and operators.The preliminary analysis was based on a desktop review ofleadingconfigurationmanagementactivityin through-lifeengineering and scoping interviewswith 1–2 personnelfrom the CAD managementand/orconfiguration management teams from Airbus, CERN (online) and Cros (in-person) as wellas a visitto Airbus premises.The scoping interviews used a protocol with starter questions includin is configuration managementdefined? Whatare the processes Flexibly linking to other sources of data, in which change may be uncontrolled as separately owned How is change managed as asset information becomes a deliverable on complex projects? Information for decision-making in delivery Project processes / ‘as designed’ Asset information as a deliverable Project outcomes / ‘as built’ Project digital systems Aggregation and links with increased datavolume, velocityandvariety Operation digital systems Fig.2.Contextforourresearch question on managing changeasasset information becomes a deliverable on complex projects. 343J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
involved in setting up this configuration management? What is the approach to configuration control? What are the challenges in terms of integration of data from as-design configuration baseline to the as-built configuration? At the end of projects did youfind differences between the as-built with the as-designed? Thecomparisonacrosscaseswasfacilitatedbyan afternoon workshop hosted in the Crossrail offices in London. The workshop in Crossrailoffices involved twenty partici- pants,with atleasttwo participants from the CAD manage- mentand/orconfiguration managementteamswithin each organization studied.This day was recorded with video;49 photographs and notes as wellas through the distribution of presentation from each organization afterwards (totaling 94 slidesfrom the3 companies).Itwasan opportunity for presentations about the context for the research; for feedback ofpreliminaryfindings;presentationsonconfiguration management from the three companies and discussion of key theoretical challenges. Followingtheworkshopweanalyzedanditerateda detailedtablethatcomparedconfigurationmanagement practices in the three collaborating organizations,in relation to topics that had arisen in the discussion at the workshop: 1) background(e.g.overview,infrastructuretype,scopeof works,budgets);2)lifecycle(e.g.typicallifecycle duration; developmenttime);3)complexity(e.g.physicalassets;asset information);4)configuration managementmotivation(cor- porate motivation, industry guidance, teams); 5)approach and systems(e.g.lifecycle breakdown,approach,data manage- ment,information systemsand supporting tool,structure of configuration items;6)managing change and change control process(e.g.changeperspective,changecontrolprocess, conformancesand non-conformances);7)risks;culturaland social issues(e.g. language, culture). The table we generated was used to visualize the data fordiscussion in the research team (Miles and Huberman, 1994),to identify salient similarities and differences, and to check details with the collaboratingfirms. We discussed thefindings in this table, which was seven pages long, to identify why all threefirms had a strong interest in configuration management and to highlight the similarities and differences. To develop our argument we reorganized our data,bringing it into dialogue with the existing literatureson the managementof projects. 4. Findings The three organizationsstudied have differentlevelsof experience ofconfiguration management.Airbus has mature processes and systems, with interest in leading developme future systems to manage and controlthe growing amountof data produced in the delivery ofcomplex products.CERN introduced configuration management in the 1990s (Bachy Hameri, 1997; Hameri, 1997; Hameri and Nitter, 2002; Ham and Puittinen,2003) and are reflecting on their approaches to configuration management,challenges and areas for improve- ment. As a major project, Crossrail is a temporary organisa established in 2008.Ithas a configuration managementteam and has drawn on industry standards (e.g.ISO, 2003) to ra embed configuration managementprocesses in the delivery of assetinformation.Motivationsgiven forusing configuration managementin managing change in these settings include th complexity of complex product systems, operational constr and the need for valid asset information. The regulated nat each ofthe industries (aerospace,nuclearresearch and civil engineering), mean these organizations all need to be able configuration items to be able to revisit designs and compl future regulation on safety-critical facilities. In Airbus, confi ration management is a strategic priority. In CERN and Cro it is an explicit activity that is addressed in organizational s using the language of managing change. 4.1. Configuration management in Airbus As an aircraft manufacturer, Airbus employs around 63,0 people in France, Germany, Spain and the United Kingdom has subsidiaries in the United States,Japan,China and India; and thefinal assembly of aircraft is in France, Germany, Sp and through ajointventurein China.Customersinclude commercialairlines.Satisfying theirevolving needs requires the design and manufacture ofnew additionsto thefleet. Airbus invests abouttwo billion euros annually in research, developmentandtechnology activities.Itoperatesin the highly regulated aerospace industry,in which each aircraft manufactured requires an individual certificate of airworthi showing itconformsto the approved design,and hasthe relevantdocumentation,inspectionsand teststo ensureit Table 2 Sources of data for the individual cases and the comparison across cases. OrganizationInteractions and observationsAssociated documentation Data on each individual case AirbusOnline call (2 participants and 2 researchers) and day-long visit to Toulouse (10 participants and 2 researchers); email clarifications. Presentation discussed in online call(20 pages)and 3 publically available presentations (79 pages). CERNOnline call and presentation (2 participants and 2 researchers); email clarifications. Internal documents (23 pages, QA procedure; status repor 2 conference papers (6 pages); and presentation (29 page CrossrailIn person interview (1 participantand 2 researchers)and ongoing collaboration. Access to internal system and documents on configuration management. Comparison across cases Airbus; CERN and Crossrail3 hourworkshop with 20 participants,recorded in 49 photographs (some video) and notes; email correspondence. Presentations from the workshop (94 slides). 344J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
willbe safe in operations.Aircraftcomponentshave strict definitionsthatincludearchitecturalnatureand materials. There are rules on how components are aggregated into sub- assemblies and assemblies to ensure the correct serviceable part is available for every configuration and operating condition. Configuration managementisone ofthe 14 Airbuskey competences, considered in procurement of the supply-chain and included as a requirement in contracts.It is well established in Airbus.There is a Centre ofCompetence where 80 internal employees and 70 externalconsultants work to editmethods, process and tools; and a significant broader capability, with more than 8000 professionals with related tasks, including 800 internal and 500 external configuration management professionals. A motivation for configuration managementis the product complexity.Itcan take more than a decade to develop a new aircraft design.Airbus produces several aircraft families,each with members and versions.No two aircraftare the same as customerscan selectbetween variantsand theproduction standardevolvescontinuously.Thenumberofpartsand combinationsofsolutionsgrow withproductcomplexity along with the combination of configurations to be managed. Product architecture includes component parts, numbering and links;with 500–1000 conceptdefinitions,with associated solutions and ways to restore previous solutions. There is a significantvolumeof data, where each aircraft has millions ofparts.The Airbus A380 plane has,forexample, about 4 million parts,with 2.5 million part numbers produced by 1,500 companies from 30 countries around the world. There is a growingvelocity,with increasing production rates,and shorterproductdevelopmentlead times.Asaircraftdesign requirescarefulanalysisofperformance data,there isalso significantvariety,with productinformation linked to struc- tured and unstructured data-setswith testresults,electrical bonding calculations,requirements from economic analyses, weight distribution, and weight calculations, etc. Configuration managementprocesses have substantialdigitalsupport,with six preferred suppliers for configuration management services. However,asthenumberofdata-setshasincreased,some information related to the aircraft is no longer well linked. For example,the functional baseline with the initialspecifications is notwelllinked with the technicalbaseline,within which change is managed once requirements are approved.Instead these are synchronised at a particular point and reset. In Airbus, a configuration item is seen as“an invariant item in the productstructure”,where each configuration item is linked to a design solution. While configuration items stay the same, the engineering baseline, used to design, gives a different view oftheproductarchitecturefrom themanufacturing baseline, which is used to install things, and both are different from the data needed in customer services. It can be difficult to recover a technical functional baseline when a big evolution is donetoastandardaircraft,wheretheinterfacebetween differentdata-sets are notlinked which means the source of data is noteasily known.A significantmilestone is the move between conceptand definition phases,where data is moved from a development environment to a production environment, which often involves differentdata structures.Atthis point, engineersmaybeinvolvedinmanuallyupdatingdata, re-numbering data-sets as well as re-defining links. Before product evolution can take place in the concept there isan important“congruency process”,through which engineering and manufacturing agree on productarchitecture and terminology.A requestforaproductevolution then involves four stages:initialization, which is the change re evaluation,which involves an evaluation study;investigation, which involves a modification proposaland consideration of technical, cost, embodiment and production repercussion implementation and closure,in which there is a fulltechnical repercussionssheet,technicaldossierandmodifications approval sheet.There are also processes for managing chan inproductidentification,andreleasinginformationfrom engineering and manufacturing information in the definit stage.Allthese process involve afinalstep thatverifies the implications of change to the product structure at higher within this complex productsystem;and ensures consistency acrossalldomains(including systems,electrical,testand technical data). Airbuswantsto improve efficiency ofthe productdata managementby achieving:scalability,through reuse of data; agility,through integration of data,andadaptability,through flexibility in integrating data changes.Configuration manage- ment challenges include: •Differentproductarchitectures–Developing agreement betweenstakeholdersinengineering,managementand customer services takes a long time. In Airbus’experie developing a complete architecture can take up to thre toagree.Afterthecongruenceprocess,theproduct architecture is the same in both engineering and manu ing and a bill of materials is produced. •A desire to be agile in a highly controlled environment. strictand rigid system developed through the congruen processlacksflexibility.Yet,even afterthe congruency process is complete there are still changes that need t place based on technology developments and the chan competitive environment that may not have been inclu the congruency process. Other challenges include the increase of product and p complexity;variety ofsoftwarevendorsand theirlack of supportforthe interfacesbetween systems;heavy load of changes to manage; communication to a growing configu management community; and shorter product developm time. 4.2. Configuration management in CERN To achieve its mission of providing scientists from arou world with tools to study the building blocks ofmatterand origins of the universe, CERN builds and operates huge p accelerators on the border between Switzerland and Fran to Geneva.Ithas approximately 2,350 staff,2,000 contractors and 10,000 visiting scientists,with an annualbudgetof about 800 million EUR.Asan integrated owner-operator,ithas 345J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
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responsibility forthe fullassetlife-cycle.Developmentand delivery of each particle accelerator is a major project. The Large Hadron Collider(LHC),forexample,involved millionsof high-tech components installed in a 27 km long circular tunnel, 100metersbelow ground,withparticlesacceleratedto 99.999999% ofthespeed oflight,corresponding to over 11,000 revolutions per second.The design phase took approx- imately 20 years,and the work was globally distributed with collaborators in more than 80 countries acrossfive continents. The material cost was approximately 3.7 billion EUR. While a lot of the design work and drafting is sub-contracted, there are about150 fulltime designers using CAD,who are engaged in designing in 2D and 3D,updating information,and upgrading designs on the different projects. A digital system for data management has been used since the late 1990s, with 5,700 active users registered on the system.The volume ofdata is significant: The whole complex involves 100 million components; with about1.5 million documents and drawings;1.6 million individually registered assets;and almost2 million equipment interventionslogged.Thevelocityofinformationinvolves about3,000 new pieces of equipmenta month,and 7,000 new documentsand drawingscreated amonth.In work on an accelerator in 2009 there were approximately 12,500 equipment interventions permonth.This data is ofsignificantvariety,it includes physics parameters, technical specifications, layouts and equipment codes (in specification); simulations, bill of materials, documents and drawings,(in design);manufacturing processes and testprocedures and results (in manufacturing);installation and safety procedures;and“as-installed”documentation (in installation); and radiation measurements,material composition, recycling procedures; and waste management (in dismantling). There is substantialinterestin configuration management within CERN with an ongoing initiative to update processes of changecontrol.Themanufacturingteam hasamature understanding ofconfiguration management,and usesthe workbreakdownstructuretomanageassetsthroughthe supply-chain,and follow up changes.Manufacturing software is linked to the digitalsystem fordata management,where manufacturing data on critical equipment can be entered. There isinterestin improving thisforthe design data including production drawings;and a desire to formalize the feedback from operation and maintenance teams as input for new designs and standardizing of parts. Challenges include the: •Extended life-cycles–Installations have lifecycles of more than 50 years, so they use historical data and formats, such as microfilm drawings,and collectmissing information by scanning and photographing the system.New assetinfor- mation will be relied on by operators in the mid-to-late 21st century, so needs to be self-explanatory and complete. •Large, complex and advanced installation–Many pieces of equipmentunique,designed specially,and the resultof many years of research and development. New accelerators and experiments must be installed into the overall system of tunnels and facilities, for example a new accelerator reused the main part of an old tunnel, with some interventions such as ground construction work to upgrade it. •Support for a scientific culture–The nature of the scienc means tolerances may be measured in microns (one mic is a thousandth of a milimetre) in an installation of sever kilometers.Yetunlikethemilitarycontextinwhich configuration managementwas developed,there is nota centralised command and control culture. The ethos is b around international research collaboration. •Major operational constraints–There is no access to tun and equipmentwhen scientific experiments are in progress. Thereisalong shut-down formaintenance work every 1–2 years,with a shorttechnicalstop every 1–2 months. Even then access is curtailed by the need to limit installe maintainersexposure to radiation;and to cool-down and warm-up equipment after and before experiments. •Regulationsfornuclearinstallations–Installersand maintainers have to waitto enter certain zones because of the radiation generated.Radiation effects are calculated for each material. Where equipment or components are inst or removed, these have to be tracked. CERN is classified a nuclear installation,so regulations are similar to a power plant,requiringtraceabledocumentationofequipment, interventions and procedures. •Parallel design work–Upgrades are managed by machin versions(2007,2009,2012,2015etc.)asdifferent acceleratorconfigurationsareworkedoninparallel. Changesincludeplannedconfigurationchangesacross versions;and interventions tofix things.When equipment is installed,itneeds tofitwith whatis there.Where there have been unexpected changes,installers have had to cut and weld equipment when installing it,modifying it on the spot to make itfit. There is particularfocus on managing such‘non-confor- mities’, where changes happen to the design during the us testing,installing or modifying the equipment.Such changes may resultin a design notbeing exactly within the specifica- tion.How the equipmentdoes notconform to specification is documented. Checks are made to establish whether equipm can be used, accepted as it is, or corrected, and how it mig corrected.Some equipmentis bespoke and extremely expen- sive, so it may be accepted despite not conforming to spec tion ifitcan be adapted on site.‘As-built’information is required formaintenance and disposal,aswellasthe next generationdesign,so testdataand new versionsofthe drawings need to be entered into the systems,along with the location of the installed equipment in the tunnel. 4.3. Configuration management in Crossrail Crossrail acts as the delivery client for a new railway, wh is due to begin operation in 2018.This £15.8 billion complex projectaims to hand-overa physicaland digitalrailway.It involvesupgradingexistingrailnetworks;buildingnew stations;boring 42 km of new tunnels across centralLondon from Paddington Station to Liverpool Street Station; installi extending and commissioning a wide array ofunderground electricalandmechanicalsystems;anddeliveringthe 346J. 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associated asset information to owners and operators. Contracts with the supply-chain require delivery of assetinformation as well as assets. There is a program of briefing the supply-chain on how to deliver this; and the quality of received information isbenchmarked,initiallyeveryquarter,andnow every 2 weeks.High quality assetinformation isrequired asthe railway is expected to operate for over 100 years. Configurationmanagementisimportantinensuringa consistent,validated setofassetinformation asaproject deliverable.Through delivery there hasbeen a smallteam focused on configuration management in a broader information management team. They are involved in developing processes for establishing and maintaining the integrity of configuration items in the preparation for hand-over. Digital system is used to manage data,where the projectmanages a significant volume ofdata,expecting to generate 2–3 million recordsin asset databases, 1 million model and drawing records; and quarter of a million GIS records.Assetinformation is stored within a repository,which is managed by data managementsoftware, with document,modeland geographic information linked to this,butrequiring differentsoftware to be viewed and edited. There is hence a significant variety of linked data in the form of assetinformation (and allthe associated variables,such as author,approver,datesand versioning);digitaldocuments, such as operationaland maintenance manuals,plans,require- ments,2D designs;parametric building informationmodels; andgeographic information, such as asset locations. Physicalassetsincluderail-tracks,trains,shaftsand buildings. The contractor is responsible for providing labels to identify assets as configuration items where practical, as well as equipment/serialnumberlabels on allequipment,unless the sizerestrictsapplication.Thelabellingofassetsenables tracking of these items.Assets are also related to other assets to represent vital‘powered by’or‘controlled by’relationships. The associated information is controlled by contractors until they deliver‘as-built’information to Crossrail.From there onwardsin the lifecycle,Crossraillocksdown information associated with configuration items,equipment/serialnumber labels, and controls any further changes internally, to ensure the integrity ofassetinformation in theirdigitalsystem.The delivery client can introduce configuration items when design has matured,from detailed design onwards.Crossrailapplies configuration controlatthe‘as-built’stage so changes to the configuration before handover are consistently maintained for the owner.There are currently around 155 thousand client configuration items, and by March 2016 the number is expected to rise over 600 thousand. Challenges include: •Rapid deploymentin a temporary organization–Interna- tionalstandardsforconfiguration and assetmanagement were important,where obtaining the‘buy-in’to establish and maintain integrity is hugely challenging in the middle of a complex mega project. •Complexity and culture of delivery–There are conflicts and interfacesamongthemanyprocessesandprocedures currently used in the industry forchanges in programme baseline,design management,red-line(marked-up)and as-builtdrawings.There are challengesin understanding theseandcreatingtheculturethatgetmanagersand engineersto understand and usetheseexisting change processes. •Multiple change processes–the configuration manage team has concluded that having multiple change proce as is currently the case within the industry is notideal, particularly where each change process may differ slig and in some the same person is assessing the impactof change and making the decision ofwhetheritshould or shouldn’t be rejected. •Establishing a requirements-led orientation–There is a need for a change from typicalmethods in the industry to mitigatetherisk ofscopecreep,by having assetsthat conform to assetinformation,which in turn conform to requirements.The red-line procedure,for example,covers the process ofannotating changes to drawings afterthey have been released forconstruction.The task,which is conducted by the site contractor,is intended to highlight approved,post-design changes from the originaldrawings, as reflected by an inspector of the built asset. The ann drawings are then transferred to Crossrail. These recor used to laterupdate the as-builtdrawingspriorto data handover to the operator. •Determining operational requirements–There are ong discussions with the future owners and operators regar the type and format of asset information that will be us operations;and aneed to future-proofthisinformation because of the long operational life. An interface to the digital system has been reconfigure facilitate this delivery ofthe large volume ofasset-specific information.Thisspecifieshow assetinformation isto be identified,named,labelled,stored,synthesized and managed. Additionalrules fornumbering and naming complementthe use ofinternationalconfiguration managementstandardsto provide robustmethods of maintaining assetinformation.By following a standard structure,and definitions,the aim is to organize asset information within the digital system and itoverto operatorsin waysthatwillbe usefulto future operation and maintenance. The interface helps users to assetrequirementstocontractors,aswellascapturethe configuration items that those contractors return.Asset labels, equipmentlabelsand serialnumbersare used to represent configuration items,as defined in three differenthierarchies based on location,function and classification.Thesystem allows metadata searching; and provides the ability to ex link groups of assets to form a single system. 4.4. Approaches to managing change Whileeach organization,Airbus,CERN and Crossrail, operates in a different industry, similarities in their appro and experienceofusing configuration managementreveal shared characteristics and challenges ofmanaging change in complex projects as assetinformation becomes a deliverable. Table 3summarises and compares the relationship betwe 347J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
projectdelivery and operations;thedataaggregation and connectionsin projectdelivery;and approach to managing change to provide asset information as a deliverable; and these topics are discussed in turn below. In summary,each ofthese organizations is interested in configuration managementin operations as wellas delivery, though they vary in the extentto which they have lifecycle responsibilities. Because Airbus has service contracts it retains an interestin aspects ofconfiguration management,such as conformity,throughoutthe lifecycle foraircraftthatithas designedandmanufactured.CERNisanintegrated owner-operator, with responsibility for the whole lifecycle. As the delivery client,Crossrailhands over assetinformation for operation and maintenance. For each organization, the complex products–aircraft, particle accelerators and railways–have a long operationallife (more than 20,50 and 100 years)so information on assets, such as material, provenance, and design rationale,need to be available to enable efficientand safe operation. Projectdelivery involves managing change in assetinfor- mation as data-sets are aggregated and re-used through life. The volume,velocity and variety of data bring new challenges of version control,linkages across projectstages and with other data-sets; and ways of structuring and organizing. While there is increasing integration between data-sets in project delivery, digitalsystemsare notseamlessly integrated,butheteroge- neous,with majortransitions in the use ofdata through the projectlife.Forexample,in Airbus,there isa significant transitionbetweenthedevelopmentandtheproduction environment,in which there ismanualwork to restructure and re-link data (there may be instances where the product does notchange,butconnections between configuration items is differentin engineering and production).Allthree organiza- tions carefully manage the upload of information to their di system because of the importance of its integrity. Where e mentproviders have relevantassetinformation,these organi- zationswilloften duplicatethatinformation in theirown systems rather than link to it, because they need to ensure stillbe available in decades to come,when the manufacturer may have differentequipmentfor sale and may notmaintain legacy information. Changeismanagedthroughthedigitalsystem,with configuration managementsoftware providing workflows for defining baselines for particular assets and assetsystems;and for assigning roles and responsibilities for approving chang This use of configuration management starts earlier in Airb than in Crossrail, where the use of configuration managem mostpronounced in the controlof as-builtinformation.Each organization has a substantial and distributed supply-chain has access to inputrelevantinformation,and to be involved in theapprovalofchangewithin projectdigitalsystems. Design globally distributed in both Airbus, with 4 million pa supplied from 30 countriesforA380,and CERN,with 80 countriesacross5 continentsinvolved in the LHC design. Crossrail has a substantial supply-chain of contractors invo in construction.Contractorswithin thissupply chain have permissions to input‘as-built’asset information into Crossr digital systems, with information approved for purpose befo is made available. Baselines are sometimes interpreted as an agreed descr of the complex product system at a point in time. This stud clarified the types of baselines now used in Airbus, CERN an Crossrail increasingly focus on assets or groups of assets. T is mostclearly articulated in Airbus,which uses functional, Table 3 Comparing how change is managed as asset information becomes a deliverable. AIRBUSCERNCROSSRAIL Relationship between project delivery and operations Organization typeService provider, with multiple customers.Integrated owner-operatorDelivery client,handing over infrastructure provider(s). ResponsibilityDesign,manufacturing,and servicing in operation. Full life-cycle.Design, construction and handover. Information as a deliverableFor customer services to monitor operational aircraft. For maintenance and upgrades to accelerators. For station and railway operators and maintainers. Responsibility for operation information Final configuration of customer’s aircraft; updating servicing information. Asset tracking; work management information; disposal information. Asset information at hand-over; not responsible for updating and maintaining. Data aggregation and connections in project delivery Interfaces in digital systemsBetween the development environment and the production environment. Across machine version; and between manufactured and installed equipment. Between the delivery client’s design and as-built asset information. Approach to managing change Configuration managementUsed in the concept, product identification and definition stages. Principles mostfamiliarin manufacturing; initiatives to reduce non-conformities. Used to manage and control as-built information; principles used in design. Configuration itemsAgreed by manufacturing and engineering through a‘congruency process.’ Different configurations of the machine managed in parallel. Identified by the delivery client and labelled by contractors. Complex productsystem– hierarchy and baselines Functional baseline for requirements; engineering baseline for design; manufacturing baseline for production and installation; Customer service baseline for technical information. Different generations of machines have baselines that are managed in parallel, making it important to get information about unplanned changes back into the design information. Configuration itemsfirst identified at detailed design stage.Contractors manage the information up to an as-built baseline. 348J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
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engineering,manufacturing and customer service baselines to manage related changes in relevantstages ofthe life-cycle. Thusthere isno longera simple baseline,butfunctional, productand other baselines managed on differenttimescales. Although in the 1950s configuration managementenabled a move backwards to the baseline, in the era of big data this is not straightforward.Re-baselining may notaccountfor different evolutionsin data unlessthese are alllinked;and there is significant work in industry to achieve this. 5. Discussion: renewed importance of configuration management in an era of‘big data’ Formanagers in these organizations thatdelivercomplex projects,configuration managementhas become more,rather than less,importantas we enteran era of‘big data’.New challengesarise asassetinformation hasbecome a project deliverable;as data increases in volume,velocity and variety; and as itis aggregated and re-used;with connections(and potentialconnections)acrossinternally and externally held data-sets. The organizations perceive a greater need for control through configuration management.The analyses suggestthe need for integrity, in assets and in asset information, is a reason forthis renewed emphasis on and interestin the associated controlprocesses,as complex projects manage a significant volume and variety of assetinformation and hand this on to ownersand operators.Ensuring integrity in operationsis essential in industries that are regulated and safety-critical but organizational complexity,large distributed supply-chains and time-pressures increase the challenge of projects delivering the asset information to support this. Configuration managementhas its origins in the mid-20th century. However, what is meant by configuration management has changed significantly. There has been a shift from relatively slow paper-based processes to fasterdatabase oriented prac- tices; and extension of configuration management practices to cover the life-cycle through articulation of multiple baselines and aspects ofthe product.Itis through such changes that configuration managementhas increased in importance as an approach to managing changein thedelivery ofcomplex projects,in an era of big data,rather than left behind with the paper-based processes of the late 20th century.There is some evidence that the speed of interaction with this data is growing, with for example Crossrail increasing the frequency with which itbenchmarksitssupply-chain from every three monthsto every two weeks.This is notjustaboutdoing change control better,butalso aboutproviding more visibility ofquality of change controlby differentparts ofthe supply-chain.Such changes are within the paradigm of configuration management: they are beginning to be reflected in related standardsand guides, with configuration management described as a compo- nent of the project management information system (PMBOK guide,2013);and,during the timeframe ofourstudy,the military developing and releasing anew interim standard (DOD,2013),having considered theuse ofa3D model, definition of as-designed, as-built and as-maintained baselines, and definition of the product(Windham,2012).Thus change management is no longer a paper-based process, as imp Fig.1,butitis predominantly concerned with digitaldata. Digital workflows become important to manage the integ of information; and conformity between requirements, sp cations and asset information. As previous research has shown that users often don’t the prescribed processes involved in configuration manag (Aliand Kidd,2014;Burgess etal.,2003;Kidd,2001;Kidd and Burgess, 2010), there are opportunities to consider w new digitaltechnologiesmightenable otherapproachesto managingchange.Airbus,CERN andCrossrailallface challenges in implementing control processes; and are ac engaged in developing new strategies. In complex projec anticipate limits to the extent to which‘big-data’will bre mould of established approaches to enable radically new andflexible form of organizing envisioned byLevitt(2011). However, we recognise the possibility of a broader shift a from baseline planning,as has occurred in software projects (Levitt,2011);or a complete transition away from principle such asdecomposition and hierarchy,asadvocated by the military(AlbertsandHayes,2003).Otherapproachesto managing change mightbe to mine data-sets to identify in- formation relevant to the operational performance of ass to seek new scalableapproachesto managing changein non-criticaldocuments,where Wikipedia,mightsuggestsa modelin which changes are made,and then corrected;which contrastswith themorebureaucratic,pre-authorisation ap- proach of configuration management. While managing change is important to project manag configuration management has had limited attention in li on complex projects. Research on complex projects has i discussed how systems integration capabilities are mobil innovation in construction (Gann and Salter,2000);and in manufacturing settings such as aircraftengine controlsystem (Brusoni et al., 2001) andflight simulation (Miller et al., 1 Thisresearchonsystemsintegration,liketheworkon configuration management, traces its history to the USA programme in the 1950s (Sapolski, 2003). Change mana through‘configuration management’relates to systems i tion,as itinvolves the decomposition of the complex produ system to identify assets, and then manage change withi assets and their associated asset information. 6. Conclusions Whilepriorresearchhasarguedthatdigitally-enabled approachesbreak themould ofestablished approachesto projectmanagement,enabling rapid,flexible forms of project organizing; in this study wefind Airbus, CERN and Crossr using relatively hierarchical, asynchronous, sequential pr esto managechange.Weconcludethattheunstructured, uncontrollednatureof‘bigdata’presentschallengesto complex projects that deliver assets. Thus this paper con by uncovering limits toflexibility where integrity is impor The potentialto use‘big data’in these contexts presents a conundrum,similarto thatdiscussed by Lagoze in science. While there is the potential for analytics to provide comm 349J. Whyte et al. / International Journal of Project Management 34 (2016) 339–351
advantage by revealing smallpatterns,‘big data’represents a paradigm shift that disrupts notions of integrity and force new ways of thinking and doing to re-establish it. It challenges the existing approachesto ensuring theintegrity ofassetsin regulated and safety critical environments. There are practical implications. Thefirst is that as managers in complex projects begin to deliver asset information, as well asassets,they should expectchangesin both assetsand associated asset information,and plan to manage this change. The second is that managers should be aware of the challenges thatan‘era of big data’presents to this process of managing change.Configuration management provides a set of tools for maintaining integrity in this context,and implementation of configuration managementhas changed and is changing as a result of digital technologies. As well as using these processes, there may be contextsin which there are opportunitiesfor managers to seek new proactive approaches to using data from projects to understanding future scenarios. Managers seeking to benefitfrom‘big data’,mustdo this while maintaining the validity ofthe information on which the delivery and main- tenance of complex product systems rely. There are also implications for research.This study returns attention to Morris’interests in the history of projectmanage- ment; the centrality of change control to good project manage- ment; and the shift from project execution to broader questions of managementof projects.There are a number of directions for further research. First, more needs to be done to understand the idea ofa baseline.Morriscritiquesthe ethosofimportant guidelines, such as the PMBOK Guide as to:“plan and then put on cruise control”(Morris, 2013: p. 282), where this misses the challenges at the front-end of projects; and the constant need for updating and modifying plans during project delivery. We need to understand more about the process of agreeing baselines; how baselines are used to managing changes in the configuration of assets,and how they are controlled across complex supply- chains.Second complex productsystems may have different hierarchicaldescriptions and hence more needs to be done to understand how configuration items are identified.There are questions aboutwhen and how the complex productsystem becomes decomposed into assets thatare then controlled,and also what information needs to be known about assets. Mapping different approaches might lead researchers to set out frameworks for understanding the kinds of change management that are most effective in differentcircumstances.Third,more needs to be understood aboutthe process of ensuring the validity of asset information in digitalsystemsthatare constantly changing, where responses are required rapidly.Here,researchers might compare models, in which changes are made, and then corrected; withthemorebureaucratic,pre-authorisationapproachof configuration management. The broader visibility and intercon- nections between data-sets provided in an era of big data may alter the utility of different approaches. Finally, there are theoretical connections to be made between the literatures.Ourwork hasrevealed particulardisconnects between the literatures on configuration managementand the strand of work on systems integration within the literature on complex projects.Further studies might explore their historical and contemporary interconnections between these,and situate concepts within broader literatures on modularity and prod architectures that may be useful in understanding change. further research will continue to chart interconnections, de by Morris,between the evolution of projectmanagementand developmentsin systemsengineering,modern management theory, and the evolution of the computer. Conflict of interest The university and authors have a strong research collab ration with Crossrail, which is indirectly and directly involve in other research, has funded consultancy and has connect through advisory boards. 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