archetypes case study part 5 june 21, 2013
DESCRIPTION
Product Development Case Study & Process Part 5TRANSCRIPT
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part 5 of 7 part Case Study
1 Product development
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Luxury brand Case Study
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Notes
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November 2012
Max Ruckman, Black & Decker HHI
Project Team
Luxury Brand
Business
Development
Case Study Part 5
www.maxruckman.com
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Agency certification
involves sample submittal, documentation, to ensure certification
Definition
leads to certification by all appropriate standards agencies
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Agency certification
documentation
Inputs
product samples
labeling
inspections
instruction manuals
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Agency certification
determine which certifications are needed
notify agencies of new product plans
perform required test
submit product samples and documentation
follow up as necessary to secure certification
Actions
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Agency certification
certification by all appropriate agencies
Deliverables
provide approval agency with prewritten report and certified test date
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Service center training
statement of the anticipated product training needs of service centers
Definition
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Service center training
sample product from engineering sample lot
existing service repair instructions and training manuals
Inputs
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Service center training
input from project team to identify any need for product training
develop a training package
obtain product sample
Actions
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Service center training
distribute a complete training package to service centers
Deliverables
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Complete engineering check
approval that the design
meets all product
specifications
Definition
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Complete engineering check
review of prototype testing verify component dimensions and assembly clearances
verify critical component dimensions and specifications are consistent with capabilities review loads, stresses, results of impact and material selection review use of standard components
verify compliance with regulatory agency specifications and other standards verification of assembly, disassembly and serviceability requirements
Definition
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Complete engineering check
drawings
tolerance studies
calculations
Inputs
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Complete engineering check
conduct review
Actions
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Complete engineering check
engineering and manufacturing approval
Deliverables
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Final component drawings
check drawings for accuracy and completeness
project engineer is responsible for obtaining sign
off on drawings by the technical and
manufacturing engineer
Definition
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Final component drawings
drawings
Inputs
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Final component drawings
review drawings
Actions
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Final component drawings
engineering & manufacturing approval
Deliverables
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Manufacturing service equipment
ensure that special equipment is available to support the service centers
Definition
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Manufacturing service equipment
recommended equipment supplier
earliest possible communication of the need for such equipment
drawings and/or samples of the proposed equipment
Inputs
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Manufacturing service equipment
identify need for the equipment
identify the supplier and contact for price & availability
receive and inspect equipment
prepare instructions for use
notify service center managers of availability
Actions
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Manufacturing service equipment
readily and available repair equipment
Deliverables
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Proof artwork
artwork approval prior to production
Definition
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Proof artwork
complete artwork
special instructions packaging purchase order
Inputs
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Proof artwork
output a final proof
review and markup of proof
sign proof
Actions
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Proof artwork
approved
proof
Deliverables
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Order QA equipment
agreement with a supplier
equipment specifications
completion dates
costs
payment plans
equipment approval plans
Definition
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Order QA equipment
approved car
new product schedule
complete equipment specifications
equipment approval plan
equipment cost
Inputs
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Order QA equipment
determine the date of equipment requirement
reach agreement on specification with supplier
reach agreement on approval plan with supplier
negotiate contract agreement with supplier
Actions
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Order QA equipment
agreed contract completion date
approved plan
cost penalties
Deliverables
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Test prototypes in the market
prototype testing
Definition
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Test prototypes in the market
test plan objectives
reliability goals
Inputs
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Test prototypes in the market
project team determines unit quantities based on statistic samples
end user prototype test
Actions
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Test prototypes in the market
results from market testing to be reviewed by project team
Deliverables
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Commit all tools
committal of all supplier tooled
components in line with the new
product introduction
Definition
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Commit all tools
complete engineering release of component designs to supplier
individual timing plans related to overall project
Inputs
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Commit all tools
organization of all funding to cover tooling design and
manufacturing of all remaining supplier tooled items
plan sampling of all tooling with regular progress reports
inspection reports supplied with all samples
Actions
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Commit all tools
components supplied within the shortest possible time in line with the project introduction program
Deliverables
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Finalize costs
review of pilot lot
cost and resolution of
deviations from the
reviewed cost in
milestone four
Definition
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Finalize costs
review cost estimate in milestone four
new information
pilot lot cost
Inputs
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Finalize costs
review actual pilot lot cost
resolve deviations
compare pilot lot and finalized estimate
Actions
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Finalize costs
frozen cost
Deliverables
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Complete prototype testing
market
tests of
the
prototype
are
complete
and results
are
compiled
Definition
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Complete prototype testing
test data
agree and approved test standard
Inputs
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Complete prototype testing
develop report
Actions
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Complete prototype testing
confirm process key variable controllability
confirm design accuracy and integrity
complete test report
Deliverables
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Complete all drawings
component,
assembly and
process drawings
should be
completed and
released
design freeze is in place
Definition
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Complete all drawings
drawings
Inputs
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Complete all drawings
engineering and manufacturing review
Actions
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Complete all drawings
engineering and
manufacturing
approval of all
drawings
Deliverables
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Service drawings bill of materials
illustrated parts list merges
the actions of creating the
service drawing, the service
bill of material, and
documenting relevant
repair information. it’s the
primary communication
document used in the repair
process
Definition
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Service drawings bill of materials
technical specifications, test
bench specifications, etc.
plant order for illustrated parts list,
allowing 8 weeks lead time
product sample from
engineering sample lot
completed bill of material and
associated parts drawings
Inputs
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Service drawings bill of materials
distribute ipl to repair centers
create service bom and technical repair information
produce service drawing (exploded view)
Actions
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Service drawings bill of materials
other part requirements
ipl that identifies the replacement parts for the product and documents pertinent repair information
Deliverables
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Confirm design FMEA’s
confirmation of the failure modes predicted by design
fmea should be confirmed by testing the product
testing to determine if the fmea was accurate
Definition
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Confirm design FMEA’s
test plan
design fmea predictions
Inputs
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Confirm design FMEA’s
test product samples to failure
Actions
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Confirm design FMEA’s
confirm ability to
meet reliability (in-
warranty) targets
expected failure mode
prediction of
normal, useful life
of the product
Deliverables
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Engineering testing
analysis techniques will be applied to the final engineering lot
Definition
units will be tested to failure
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Engineering testing
quantities
test types
test plan
Inputs
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Engineering testing
complete analysis to test
Actions
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Engineering testing
analysis to yield
reliability statistics to
be applied during
ongoing quality
assurance testing of
production built units
Deliverables
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First samples
project
management of
supply base
provides usable
parts for first build
from production
process within
project timing
Definition
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First samples
minimum design
changes
managed to
minimize effect
supplier timing plans
Inputs
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First samples
coordination of raw material procurement
management of communication, changes etc.
preparing suppliers
Actions
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First samples
activity timing plan to achieve part and process approval
details for critical dimensions
parts sampled on
time and suitable
for initial test work
Deliverables
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Critical & full FPL’s
insure piece
inspections are
complete and all
deviations are
satisfactorily
resolved
Definition
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Critical & full FPL’s
first piece inspections
Inputs
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Critical & full FPL’s
resolve all deviations - implement drawing, tooling or equipment changes as required
Actions
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Critical & full FPL’s
all engineering dispositions resolved before project team is dissolved
acceptable accurate drawings
acceptable accurate components
Deliverables
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Engineering build & test
engineering
built samples
to be tested
according to
predetermined
test plan
Definition
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Engineering build & test
description of sample’s construction
engineering build samples
test plan
Inputs
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Engineering build & test
comprehensive
feedback to the project
team on test results
test samples
Actions
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Engineering build & test
test report
Deliverables
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Deliver equipment
physical location
may be a
company facility
or an outside
supplier’s site
transfer of
equipment
ownership from
supplier to
manufacturer
Definition
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Deliver equipment
acceptable components with full fpl’s
completed equipment approval plan
equipment approval plan
Inputs
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Deliver equipment
approval of
final destination
physical relocation
to production site
take possession
of equipment
Actions
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Deliver equipment
a sustainable process
ready to run equipment
Deliverables
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Field testing
conduct field
testing on final
sample lot
Definition
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Field testing
reliability targets
project team to
determine unit
quantities and test
results to be
available by pilot
lot testing
completion
Inputs
83
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Field testing
conduct field testing
Actions
84
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Field testing
results from market testing to be appraised by
statistical methods the project team in conjunction
with the pilot lot results to confirm bulk release
Deliverables
85
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Patent review
detailed review to
indentify any
infringement risk
and to identify any
patentable
features resulting
from changes in
design features
Definition
86
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Patent review
engineering built units
all engineering drawings
Inputs
87
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Patent review
review by legal and engineering
Actions
88
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Patent review
patent filings
written opinion by legal
Deliverables
89
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All quality plans complete
all quality plans
must be complete
and available for
use in
manufacturing
Definition
90
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All quality plans complete
component quality plans
unit quality plan
audit quality plan
pilot lot test plan
lot 2 test plan
feasibility test plan Inputs
91
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All quality plans complete
determine all quality plans are complete and accurate
Actions
92
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All quality plans complete
working
documents
ready for use
Deliverables
93
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Sample lot one & test
sample lots will be built using production processes and controls
manufacturing is responsible for preparing and ordering material
sample lot build is the first evaluation of production capability
Definition
94
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Sample lot one & test
sample testing includes test compliance evaluation and submittals
determine if changes after engineering build affected performance
quantity should be 60 to 100 units
Definition
95
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Sample lot one & test
material
fixtures
test plan
Inputs
96
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Sample lot one & test
test sample lots
Actions
97
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Sample lot one & test
functional product, test results
Deliverables
98
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Order long lead material
manufacturing is
responsible for
ordering long lead
parts and
materials for
additional samples
Definition
99
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Order long lead material
bill of material
capital
expense funding
Inputs
100
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Order long lead material
comprehensive test result
feedback to the project team
test samples
Actions
101
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Order long lead material
purchase orders
Deliverables
102
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Tool s & modifications
alignment of
manufacturing
process to design
needs as a result of
part measurement
and product testing
Definition
103
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Tool s & modifications
measurement
resource supplier
resource to
progress activity
ecn’s
fpl reports
Inputs
104
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Tool s & modifications
effective implementation of approved design changes
analysis of proposed design changes
analysis of report and coordination of tool/process correction activity
Actions
105
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Tool s & modifications
all processes capable of producing to predetermined tolerances
appropriate standards in place
all parts approved
Deliverables
106
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Confirm cost
review of production costs and resolution
of deviations from the final cost
Definition
107
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Confirm cost
new information
pilot lot costs
finalized cost estimate
Inputs
108
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Confirm cost
resolve deviations from initial processing assumption
compare pilot lot and finalized estimate of processing cost
review actual pilot lot product costs
Actions
109
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Confirm cost
frozen cost entered in standards
Deliverables
110
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Packaging available
delivery of
packaging
that meets all
quality and
delivery
expectations
Definition
111
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Packaging available
purchase order
approved final proof
Inputs
112
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Packaging available
produce packaging boards
deliver to manufacturing plant
Actions
113
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Packaging available
finished
packaging
delivered
on schedule
Deliverables
114
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Safety hazard reviews complete
safety issues identified during the safety reviews must have been corrected. “no safety issues remain
Definition
115
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Safety hazard reviews complete
Inputs
product design
safety reviews
accident reports
customer complaints
field failures
review possible product misuse that could result in safety issues
116
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Safety hazard reviews complete
determine if any safety issues remain
Actions
117
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Safety hazard reviews complete
a safe product – all safety issues eliminated
Deliverables
118
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Final sample lot & test
additional sample lots should be built and tested if significant changes are
made in the production process or if tests indicates that changes in
production process have affected production performance or reliability
Definition
119
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Final sample lot & test
confirm analysis from previous sample lots
sample lot build and testing is complete when no additional design
changes, process changes, or tooling modifications are required
Definition
120
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Final sample lot & test
materials
fixtures
test plan
Inputs
121
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Final sample lot & test
provide comprehensive feedback on test results to the project team
Actions
122
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Final sample lot & test
functional product
test results
Deliverables
123
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Approve & order parts
management of
supply base of
components from
start-up to full
production
Definition
124
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Approve & order parts
supplier confirmation of capacity for bulk production
released engineering structure and all parts approved for construction
detailed component and raw material lead times
demand & ramp-up profile
Inputs
125
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Approve & order parts
commit to production schedule
Actions
126
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Approve & order parts
flexibility to
respond to
changes in
demand
parts to specification in-line with production plan
Deliverables
127
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Approve capital equipment
complete approval plan to verify that
equipment meets all specifications
Definition
128
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Approve capital equipment
safety approval – safety engineering
results of complete plan runoff - acceptable components with full fpl’s if required
equipment approval plan
Inputs
129
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Approve capital equipment
resolve any deviations
process control capacity/cycle time
capability fpl’s
Cost
fpl’s
Actions
agree equipment meets all specifications
130
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Approve capital equipment
acceptance or rejection of equipment
Deliverables
131
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Confirm process fmea’s
test the product to failure – determine if fmea was accurate
confirmation of the failure modes predicted by the fmea
Definition
132
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Confirm process fmea’s
test plan
fmea predictions
Inputs
133
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Confirm process fmea’s
test product
samples to failure
Actions
134
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Confirm process fmea’s
production test rate, test
method and production
shut down criteria
expected process problems
a prediction of the
reliability and
capability of the
process used
Deliverables
135
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Pilot lot & test
pilot lot production is a verification of the capability of the production process
pilot production must be run through only production process, components that have
acceptable fpl’s, scheduling, controls, fixtures, gauging and personnel
all production must be saleable product and sufficient quantity (80% of full planned production per shift)
must be run to verify process capabilities and meet testing and test market requirements
Definition
136
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Pilot lot & test
pilot lot test is a verification that production processes have not adversely affected the performance and
reliability of the product
the pilot production must be tested to the same standards as the sample lot production and
comparable test results must be obtained
Definition
137
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Inputs
Pilot lot & test
successful sample lot test results
no design changes no tooling changes no process changes final packaging pilot lot level components final tooling and manufacturing
equipment material, fixtures test plan agency certification final cost
clean sample lot
138
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Pilot lot & test
saleable product that is not committed to a customer
Deliverables
139
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November 2012
Max Ruckman, Black & Decker HHI
Project Team
Luxury Brand
Business
Development
Case Study Part 5
www.maxruckman.com
140