Monday, February 18, 2013

Imperfect People Build Imperfect Systems

I've done a lot of work over the decades on systems that were expected to be fault-tolerant and highly reliable. These projects ranged from enormous geographically-distributed enterprise communications systems that spanned national boundaries, to tiny sensor networks that are part of an environmental control system. I've done a lot of reading on best practices for developing fault-tolerant, high-reliability systems at all scales, and have done my best to incorporate those learnings into my own product development work.

But because imperfect people build imperfect systems, I also did a lot of reading on how humans muck things up more or less inevitably. Here are some of the books I recommend, in the order that I read them, and what I took away from them.

James R. Chiles, Inviting Disaster: Lessons from the Edge of Technology, HarperBusiness, 2001

In 1982, during a storm off the coast of Newfoundland, the drilling rig Ocean Ranger capsized and sank with its crew of eight-four men. There were no survivors. The British rigid airship R101 was largest flying machine ever built, and would remain so until Germany built the Hindenburg some year later. When the R101 made its maiden voyage in 1929, it was unable to keep its own weight airborne, shearing off the roofs of cottages in the English countryside, until it finally crashed, killing forty-eight of the fifty-four people on board. In 1979, World War III was narrowly averted when a training tape was inadvertently inserted onto the screens of four U. S. command centers with no indication that it was a simulation.

These are just three of the dozens of case studies that Chiles presents and dissects in his book. Some of them are more familiar: Apollo 13, the Challenger space shuttle, Three Mile Island, and Chernobyl. Chiles' book manages to be both fascinating and horrifying.

Many of these disasters were the result of ordinary mistakes made in extraordinary circumstances. Sometimes the people involved didn't realize a disaster was in the offing. Sometimes they chose to ignore the evidence right in front of them. Often they depended on their own unreliable intuition, a failure in cognition that will be reiterated in the book below by Dörner. Transitions are the time of the greatest chance of making mistakes or of errors occurring. Sometimes folks did not appreciate the scale of risk even when the probability of failure was low. Sometimes they did not appreciate the hidden technology buried deep in the systems they were using. Valiant heroism often occurs in the midst of disasters, but unlike the movies, seldom succeeds.

The leaders of an organization have tremendous influence, sometimes unwittingly and unknowingly, on safety, or the lack of it, through their own attitudes and prioritization, which affect the organization's culture. And a common theme in these case studies is how leaders seldom insist on hearing bad news; in fact, subordinates are punished for bringing bad news upstairs. Chiles also talks about how important it is to "fill in the cracks": make minor course corrections before small mistakes expand into systemic breakdowns.

For me, one of the biggest lessons from this book is that we frequently do not design systems to recover from multiple failures that occur simultaneously. It's just too hard to think about, and it seems so unlikely. Yet it was that kind of impossible chain of independent failures that just happened to line up in time that lead to the deaths of the crew of the Ocean Ranger.

Dietrich Dörner, The Logic of Failure: Recognizing and Avoiding Error in Complex Situations, Basic Books, 1996

Dörner is a psychologist whose book describes series of computer simulations with a wide variety of volunteers that required each to deal with a dynamic system with interrelated components. His goal was to discover the common cognitive errors humans make when trying to manage such systems.

For example: an African tribe whose livelihood depends on herds of cattle and sheep, which depend on the grassland, which depends on the water table. Well meaning participants in the simulation would bring Western health care to the tribe. The mortality rate would go down. The population would go up. The number of animals necessary to support the tribe would rise. The amount of grass necessary to feed the herds would outstrip the water supply. Famine would result. In fact, pretty much anything the simulation participants tried to do to improve the lot of the tribe would ultimately, sooner or later, result in famine.

The game wasn't rigged. The system was just the beyond the capability of most people, even trained economists and ecologists, to understand all the interdependencies when they had to discover them in real-time and make iterative decisions. The irony is that if the participants had just stood back and done nothing, the tribe would have been fine. Natural forces had, over many years, optimized all the components in the system for the available resources. Another simulation involving a watch factory in a small European community had similar results.

It was hard not to think about capitalism and market forces versus communism and central management when reading this book, even though I don't recall the author making that comparison explicitly. Dörner compares the results of these simulations with real-life mistakes that often had disastrous consequences, such as Chernobyl.

Humans suck at understanding and managing dynamic systems. Systems may have limited resources with only a certain amount of buffering between interrelated components. Variables in the system may have relationships exhibiting both positive and negative feedback. We are too quick to apply our own conditioned responses to situations that are different from those we have experienced before. We ignore what has been successfully done by others before -- frequently for very good reasons -- in the same circumstances. We try to make abstractions which can result in hiding or discarding vitally important detail.

The author remarks that many of these cognitive mistakes are probably the result of economizing the scarce and slow resource that is human thought. He talks about the necessity of "redundancy of potential command", by which he means the delegation of decision making to empowered subordinates, a point that Gawande will reiterate in his book below. His studies also suggest that we are highly motivated by a desire to preserve a positive view of our own competence, sometimes with deadly consequences. One of the big take aways from this book is the need for communication in organizations, both vertically and horizontally, and the absolute requirement for empowered delegation, bringing a kind of distributed and parallel processing to the human domain.

Two great quotes:

"Advocates of progress often have too low an opinion of what already exists."
-- Bertolt Brecht

"One jumps into the fray, then figures out what to do next."
-- Napoleon

Atul Gawande, The Checklist Manifest: How to Get Things Right, Picador, 2009

Mrs. Overclock, a.k.a. Dr. Overclock, Medicine Woman, read this book and passed it along to me. I'm glad she did. Gawande is a surgeon in Boston, a MacArthur fellow, and author, who participated in a World Health Organization project to improve surgical outcomes and reduce complications. Not just in the kinds of places you might expect WHO to operate, but in places like the United States, Britain, and New Zealand.

The result was the evolution of a series of checklists. I mean literally: a poster on the wall or a page on a clipboard with just a few brief bullet items on it, listing simple but important tasks that must have been completed, to be read, reviewed, and verified at pre-defined pause points during the surgery: before anesthetic is administered, before the incision is made, before the patient leaves the operating room.

The use of surgical checklists has lead to a drastic reduction in post-operative complications like infection, and has saved tens of millions of dollars, not to mention many many lives.

WHO Surgical Safety Checklist

This will seem all quite familiar to the aviators in my audience. Gawande devotes much of the book to describing how checklists evolved from the early days of aviation, when it seemed that multi-engine aircraft might be too complicated for humans to fly, and how checklists, both notebooks and computerized, are now a routine part of every flight, commercial or private. He also talks about how checklists, in the form of project management charts, have enabled construction firms to build skyscrapers and nuclear submarines, keeping track of thousands of details and tasks for hundreds of skilled craftspeople. And he talks about the role of checklists in the safe ditching of U. S. Airways flight 1549 in the Hudson river in 2009.

Like the books mentioned above, Gawande talks about the cognitive weaknesses in humans, in this case to deal with fine levels of detail. He talks about the difference between the simple, the complicated (lots of moving parts, but once an algorithm is discovered, success is easily repeatable), and the complex (every situation is unique). Humans are not wired for complicated, but we may the only ones that can tackle the complex. My friend, occasional colleague, and embedded wonk John Lowe likes to say, in tone of voice that is a combination of wistful and ironic: "If only there were a machine that could somehow take mundane, repetitive tasks, and automate them...". For many complicated jobs, the checklist is that machine.

The author discusses the difference between a do-confirm checklist and a read-do checklist. He also talks about the need for both task actions and coordination actions, the latter being a pre-programmed time to touch bases with the those involved to make sure everyone is on the same page. In various contexts, this may be called a meeting, a briefing, a huddle, or a scrum.

A good checklist -- and there is a lot of effort that goes into creating and refining a good checklist -- has enormous leverage. While a single instance of a failure may affect only one person, that class of failure can affect many. Eliminating it has broad consequences. A good checklist is one that gets used. For that to happen, checklists should have only five to nine items, about the same size as short term memory, and should take only sixty to ninety seconds to go through.

One of the things that makes checklists difficult to adopt is ego: some professionals feel the checklist usurps their authority, particularly when it is a subordinate reading the checklist. But those professionals suck at the fine detail, as much as they would like to think they do not. Surgeons and pilots use checklists because the checklist helps them succeed.

I will continue to read about failures -- in both technology and people -- and about how to prevent them. We could use a dose of fault-tolerance and high-reliability in both our systems and ourselves.

Saturday, February 02, 2013

When You Are Compelled To Create

Linds Redding was a New Zealand-based graphic designer, art director, and animator who spent decades in the advertising industry until he died in October of esophageal cancer. In March he wrote an article for his blog, very widely disseminated among folks in that industry, in which he looked back at his long career. He was writing from the point of view of a creative who knew he was going to die soon. What he says seems to me to be remarkably applicable to other fields of endeavor, maybe even universally so. I would like to write a blog article of my own on this topic, but I could not improve on what Redding has to say. You're better off reading the original article.

A Short Lesson in Perspective

Should Redding's blog disappear, his article can also be found here in its entirety.

The fact is: we are all creatives who are going to die soon.

Many thanks to my friend Mike Kiss for passing this along.

Thursday, January 31, 2013

We Shape Our Tools And Then Our Tools Shape Us

Or so said (maybe) Marshall McLuhan, a philosopher and communication theorist best known for the phrase "The medium is the message." And because our tools shape us, it pays to have the best tools you can afford. When you say "tools" to a software developer, the first thing that pops into their head are software development tools like Eclipse, an interactive development environment with a graphical user interface. And for sure, I use Eclipse on an almost daily basis. But for the kind of work I do, down close to bare metal, this can also mean artifacts ranging from hand tools like wrenches and screwdrivers to high-technology tools like logic analyzers and digital storage oscilloscopes.

I have three tool kits that I put together over the past few years that have served me well. I didn't just go out to the hardware store and buy a bunch of tools that I thought might be useful. I carefully collected the tools I found indispensable and organized them into cases and bags that I could cart around in the trunk of my car from client to client as the need arose. I learned to do this from working closely with really excellent field support engineers who had to wrench and troubleshoot some of the products that I produced during my long career.

Field-Service Tool Kit

This is a big professional field-service bag about the size of a small suitcase. It is shown with my iPhone for comparison. It is stuffed with twenty-four pounds of hand tools. That may not sound like that much until you cart them up several flights of stairs.

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The field-service tool kit has two enormous zip-open compartments. The first one looks about like what you would expect: wire cutters and strippers, pliers, wrenches, screwdrivers, EMT scissors and other sharp objects capable of various degrees of mayhem, as well as more esoteric stuff like ESD-safe tweezers, a barb-wire-fence tool (invaluable), some pipecleaners, and a toothbrush. If you buy quality hand tools for your own use, you will recognize a lot of this stuff.

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The other side of the bag contains a variety of specialized equipment like my Radio Shack digital multimeter and a variety of probes for it, a big zip-lock bag of neon-colored nylon ties, and electrical and duct tape.

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Not shown are the outside velcro-closing pockets with safety glasses, flashlights, spools of wire of various gauges, and a big zip-lock bag of miscellaneous crimp-on connectors.

Console and Signals Tool Kit

This is a laptop bag, with my iPhone for comparison, stuffed with the things I need to instrument a microprocessor or microcontroller to see what the heck my software or firmware, or my client's hardware, is doing.

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The console and signals tool kit includes a Velleman PCSU1000 PC-based digital storage oscilloscope (left), a Saleae Logic-16 PC-based logic analyzer (right), a powered USB 2.0 hub (bottom), and an old IBM ThinkPad (center). The laptop runs Windows 7 and is loaded with the Velleman and Saleae software, as well as packages like WireShark, the Ethernet protocol analyzer formerly known as Ethereal, and PuTTY, my favorite Windows-based terminal emulator. The tool kit also includes a wide selection of USB adaptors for RS232 and logic-level serial ports and other serial busses, as well as a bunch of USB, Ethernet, and serial cables.

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All of this, and more, gets packed into the laptop bag so that a short trip to my car can get me started quickly figuring out what's going on.

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The console and signals tool kit is the one I use the most often.

Soldering Station Tool Kit

Occasionally I have to do more violence, in the form of hardware mods or repairs, than you might expect for someone whose degrees are all in Computer Science. That's when this backpack moves into the trunk of the car.

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It contains a complete Weller digitally-controlled soldering station and all the paraphernalia that goes with it. Plus: safety glasses with magnifying lenses, alligator-clip "helping hands" with a magnifying glass, a folding super-bright LED task light (you may be detecting a pattern here), and even a Weller ESD-safe heat gun and a collection of shrink wrap tubing.

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All of this, plus a flux pen and other useful stuff, fit comfortably in the backpack, the soldering station and heat gun inside their original boxes.

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I've used this tool kit to do quite professional-looking (considering the practitioner) work, building special adapters and cables and test fixtures and what-not. And sometimes, not so professional work like scraping surface mount resistors off a board and replacing them with conventional resistors to which I could attach a logic analyzer.

I have had clients that knew that they needed an embedded developer, but had no real clue what an embedded developer did or what tools he needed to fulfill his role in their product development organization. These tool kits allow me to become a self-sufficient one-man traveling R&D laboratory. When they hire me, they're getting a bunch of necessary infrastructure too. I've already figured out what I need, so they don't have to.

Update (2013-02-09)

Network Tool Kit

While having breakfast when three friends this morning, conversation inevitably turned towards using Wireshark to debug TLS packet streams. Well, maybe not inevitably, but that's the kind of friends I have. I realized then that I forgot about my network tool kit.

Network Tool Kit Closed

This bag contains four smaller bags or sub-kits. The sub-kits contain (clockwise from top left) a LinkSys WRT54GL wireless broadband router (this is the Linux-based model), an inexpensive Dynex IP router, a Netgear FS108 fast Ethernet switch, and a Netgear EN104 Ethernet hub. Plus, all the necessary AC adapters and cables to deploy them.

Network Tool Kit Subkits

I've used the LinkSys access point to debug and test WiFi chips in embedded systems. The Dynex router is useful to set up a temporary IP subnet in a laboratory and isolate weirdness from the client network. The Netgear switch is handy for expanding the single Ethernet cable the client gives me into a usable eight-port network. And if you've ever done Wireshark debugging, you know that as obsolete as it may be, the Ethernet hub is invaluable for peeking at a network packet stream between devices.

Network Tool Kit Components

All four sub-kits, plus an array of Ethernet patch cables, fits in this small bag.

Network Tool Kit Open

I don't use my network kit that often, but when I need it, I really need it.

Update (2013-12-24)

Air Travel

I was recently called upon to do some cross country travel on behalf of one of my clients to do some product integration testing with one of their big customers. I used this as an excuse to try out my recently upgraded field support capability. Considering past clients have shipped me off to Europe and Asia, I'd like to think my business card could say: "Have Laptop - Will Travel".

I replaced my laptop bag with a Pelican U100 Elite backpack.  If the U.S. Navy Seals had to do field support, this is what they would use. The U100 has a built-in Pelican case for my field service laptop. The case has the usual dust and moisture seals and pressure equalization valve that has made Pelican the standard by which all other such field cases are measured.

Pelican U100 Laptop Backpack

Some time ago I replaced my ancient IBM ThinkPad mentioned earlier in this article with a Lenovo ThinkPad T430s laptop. This is Lenovo's standard rugged business ThinkPad equipped with a solid state disk (SSD). I find eliminating moving parts as much as possible makes it more likely my equipment will arrive at its destination fully functional. Since the U100 backpack with the T430s resides in the trunk of my all-wheel-drive Subaru,  I worry about it a lot less. The U100 carries not only the T430s, but also my Saleae Logic PC-based logic analyzer, my Velleman PCSU1000 PC-based oscilloscope, a small multimeter, USB adapters, cables, connectors, and other tools of the trade.

Pelican U100 Laptop Backpack (Open)

The U100 is small enough to carry-on, but some of the tools I carry in it are not TSA-friendly. When I have to travel with it as checked baggage, I stow it in a North Face Base Camp duffel bag. The mouth of the North Face duffel is big enough to swallow the U100 backpack whole.

North Face Base Camp Duffel Bag (Open)

I've sat on flights that have just landed, waiting my turn to deplane, and watched my luggage sit on the tarmac in the pouring rain. The water resistant North Face duffel not only protects my equipment from the elements, but keeps the straps of the U100 out of the workings of hungry automated baggage systems. Although the duffel comes with detachable shoulder straps, I find that the built-in handles are completely adequate to temporarily turn the duffel into a backpack while shlepping it through airports.

North Face Base Camp Duffel Bag (Closed)

When I have to travel with additional equipment, I once again turn to Pelican. The relatively small Pelican 1510 case meets the carry-on requirements of most airlines and is designed like carry-on rolling luggage.

Pelican 1510 Carry-On Rolling Bag (Closed)

It doesn't hold as much as you might think, thanks to all the internal padding and the thick plastic shell. But the padding and shell are exactly why I bought the case in the first place. It was sufficient on my recent trip to carry an engineering prototype of a satellite communications product, a power supply, a tangle of cables, and a quarter-terabyte USB 3.0 drive (!!!).

Pelican 1510 Carry-On Rolling Bag (Open)

When I reach my destination, I extend the handle of the 1510, set it up on its built-in wheels, stack my other paraphernalia on top of it, and I'm good to go.

Pelican 1510 Carry-On Rolling Bag

When I am traveling on the business of high technology, it doesn't pay to scrimp. My mission may be critical enough that there really is no Plan B. And when I am dealing with my clients, or even more importantly the clients of my clients, I want to project an image of competence, quality, and professionalism. I want to keep my current business; and I never know from where my future business is going to come.