Archetypes case study part 5 june 21, 2013

part 5 of 7 part Case Study

1 Product development

Luxury brand Case Study

2

Notes

3

November 2012

Max Ruckman, Black & Decker HHI

Project Team

Luxury Brand

Business

Development

Case Study Part 5

www.maxruckman.com

4

Agency certification

involves sample submittal, documentation, to ensure certification

Definition

leads to certification by all appropriate standards agencies

5


documentation

Inputs

product samples

labeling

inspections

instruction manuals

6


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

7


certification by all appropriate agencies

Deliverables

provide approval agency with prewritten report and certified test date

8

Service center training

statement of the anticipated product training needs of service centers

Definition

9


sample product from engineering sample lot

existing service repair instructions and training manuals

Inputs

10


input from project team to identify any need for product training

develop a training package

obtain product sample

Actions

11


distribute a complete training package to service centers

Deliverables

12

Complete engineering check

approval that the design

meets all product

specifications

Definition

13


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

14


drawings

tolerance studies

calculations

Inputs

15


conduct review

Actions

16


engineering and manufacturing approval

Deliverables

17

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

18


drawings

Inputs

19


review drawings

Actions

20


engineering & manufacturing approval

Deliverables

21

Manufacturing service equipment

ensure that special equipment is available to support the service centers

Definition

22


recommended equipment supplier

earliest possible communication of the need for such equipment

drawings and/or samples of the proposed equipment

Inputs

23


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

24


readily and available repair equipment

Deliverables

25

Proof artwork

artwork approval prior to production

Definition

26

Proof artwork

complete artwork

special instructions packaging purchase order

Inputs

27

Proof artwork

output a final proof

review and markup of proof

sign proof

Actions

28

Proof artwork

approved

proof

Deliverables

29

Order QA equipment

agreement with a supplier

equipment specifications

completion dates

costs

payment plans

equipment approval plans

Definition

30

Order QA equipment

approved car

new product schedule

complete equipment specifications

equipment approval plan

equipment cost

Inputs

31

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

32

Order QA equipment

agreed contract completion date

approved plan

cost penalties

Deliverables

33

Test prototypes in the market

prototype testing

Definition

34


test plan objectives

reliability goals

Inputs

35


project team determines unit quantities based on statistic samples

end user prototype test

Actions

36


results from market testing to be reviewed by project team

Deliverables

37

Commit all tools

committal of all supplier tooled

components in line with the new

product introduction

Definition

38

Commit all tools

complete engineering release of component designs to supplier

individual timing plans related to overall project

Inputs

39

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

40

Commit all tools

components supplied within the shortest possible time in line with the project introduction program

Deliverables

41

Finalize costs

review of pilot lot

cost and resolution of

deviations from the

reviewed cost in

milestone four

Definition

42

Finalize costs

review cost estimate in milestone four

new information

pilot lot cost

Inputs

43

Finalize costs

review actual pilot lot cost

resolve deviations

compare pilot lot and finalized estimate

Actions

44

Finalize costs

frozen cost

Deliverables

45

Complete prototype testing

market

tests of

the

prototype

are

complete

and results

are

compiled

Definition

46


test data

agree and approved test standard

Inputs

47


develop report

Actions

48


confirm process key variable controllability

confirm design accuracy and integrity

complete test report

Deliverables

49

Complete all drawings

component,

assembly and

process drawings

should be

completed and

released

design freeze is in place

Definition

50


drawings

Inputs

51


engineering and manufacturing review

Actions

52


engineering and

manufacturing

approval of all

drawings

Deliverables

53

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

54


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

55


distribute ipl to repair centers

create service bom and technical repair information

produce service drawing (exploded view)

Actions

56


other part requirements

ipl that identifies the replacement parts for the product and documents pertinent repair information

Deliverables

57

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

58


test plan

design fmea predictions

Inputs

59


test product samples to failure

Actions

60


confirm ability to

meet reliability (in-

warranty) targets

expected failure mode

prediction of

normal, useful life

of the product

Deliverables

61

Engineering testing

analysis techniques will be applied to the final engineering lot

Definition

units will be tested to failure

62

Engineering testing

quantities

test types

test plan

Inputs

63

Engineering testing

complete analysis to test

Actions

64

Engineering testing

analysis to yield

reliability statistics to

be applied during

ongoing quality

assurance testing of

production built units

Deliverables

65

First samples

project

management of

supply base

provides usable

parts for first build

from production

process within

project timing

Definition

66

First samples

minimum design

changes

managed to

minimize effect

supplier timing plans

Inputs

67

First samples

coordination of raw material procurement

management of communication, changes etc.

preparing suppliers

Actions

68

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

69

Critical & full FPL’s

insure piece

inspections are

complete and all

deviations are

satisfactorily

resolved

Definition

70


first piece inspections

Inputs

71


resolve all deviations - implement drawing, tooling or equipment changes as required

Actions

72


all engineering dispositions resolved before project team is dissolved

acceptable accurate drawings

acceptable accurate components

Deliverables

73

Engineering build & test

engineering

built samples

to be tested

according to

predetermined

test plan

Definition

74


description of sample’s construction

engineering build samples

test plan

Inputs

75


comprehensive

feedback to the project

team on test results

test samples

Actions

76


test report

Deliverables

77

Deliver equipment

physical location

may be a

company facility

or an outside

supplier’s site

transfer of

equipment

ownership from

supplier to

manufacturer

Definition

78

Deliver equipment

acceptable components with full fpl’s

completed equipment approval plan


Inputs

79

Deliver equipment

approval of

final destination

physical relocation

to production site

take possession

of equipment

Actions

80

Deliver equipment

a sustainable process

ready to run equipment

Deliverables

81

Field testing

conduct field

testing on final

sample lot

Definition

82

Field testing

reliability targets

project team to

determine unit

quantities and test

results to be

available by pilot

lot testing

completion

Inputs

83

Field testing

conduct field testing

Actions

84

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

Patent review

detailed review to

indentify any

infringement risk

and to identify any

patentable

features resulting

from changes in

design features

Definition

86

Patent review

engineering built units

all engineering drawings

Inputs

87

Patent review

review by legal and engineering

Actions

88

Patent review

patent filings

written opinion by legal

Deliverables

89

All quality plans complete

all quality plans

must be complete

and available for

use in

manufacturing

Definition

90


component quality plans

unit quality plan

audit quality plan

pilot lot test plan

lot 2 test plan

feasibility test plan Inputs

91


determine all quality plans are complete and accurate

Actions

92


working

documents

ready for use

Deliverables

93

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


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


material

fixtures

test plan

Inputs

96


test sample lots

Actions

97


functional product, test results

Deliverables

98

Order long lead material

manufacturing is

responsible for

ordering long lead

parts and

materials for

additional samples

Definition

99


bill of material

capital

expense funding

Inputs

100


comprehensive test result

feedback to the project team

test samples

Actions

101


purchase orders

Deliverables

102

Tool s & modifications

alignment of

manufacturing

process to design

needs as a result of

part measurement

and product testing

Definition

103


measurement

resource supplier

resource to

progress activity

ecn’s

fpl reports

Inputs

104


effective implementation of approved design changes

analysis of proposed design changes

analysis of report and coordination of tool/process correction activity

Actions

105


all processes capable of producing to predetermined tolerances

appropriate standards in place

all parts approved

Deliverables

106

Confirm cost

review of production costs and resolution

of deviations from the final cost

Definition

107

Confirm cost

new information

pilot lot costs

finalized cost estimate

Inputs

108

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

Confirm cost

frozen cost entered in standards

Deliverables

110

Packaging available

delivery of

packaging

that meets all

quality and

delivery

expectations

Definition

111

Packaging available

purchase order

approved final proof

Inputs

112

Packaging available

produce packaging boards

deliver to manufacturing plant

Actions

113

Packaging available

finished

packaging

delivered

on schedule

Deliverables

114

Safety hazard reviews complete

safety issues identified during the safety reviews must have been corrected. “no safety issues remain

Definition

115


Inputs

product design

safety reviews

accident reports

customer complaints

field failures

review possible product misuse that could result in safety issues

116


determine if any safety issues remain

Actions

117


a safe product – all safety issues eliminated

Deliverables

118

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


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


materials

fixtures

test plan

Inputs

121


provide comprehensive feedback on test results to the project team

Actions

122


functional product

test results

Deliverables

123

Approve & order parts

management of

supply base of

components from

start-up to full

production

Definition

124


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


commit to production schedule

Actions

126


flexibility to

respond to

changes in

demand

parts to specification in-line with production plan

Deliverables

127

Approve capital equipment

complete approval plan to verify that

equipment meets all specifications

Definition

128


safety approval – safety engineering

results of complete plan runoff - acceptable components with full fpl’s if required


Inputs

129


resolve any deviations

process control capacity/cycle time

capability fpl’s

Cost

fpl’s

Actions

agree equipment meets all specifications

130


acceptance or rejection of equipment

Deliverables

131

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


test plan

fmea predictions

Inputs

133


test product

samples to failure

Actions

134


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

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

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

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

Pilot lot & test

saleable product that is not committed to a customer

Deliverables

139

November 2012

Max Ruckman, Black & Decker HHI

Project Team

Luxury Brand

Business

Development

Case Study Part 5

www.maxruckman.com

140

Archetypes case study part 5 june 21, 2013

Business

service centers12

service centers22

service center traininginput

test prototypes

product samples

complete training package

product sample11

manufacturing approval17