Felix Sanchez From Research Prototype to Production Project Management for ARA Engineers and Scientists.

Felix Sanchez

From Research From Research Prototype to ProductionPrototype to Production

Project Management for ARA Engineers and Scientists

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Desired Learning ObjectivesDesired Learning Objectives Recognize what preplanning is required to take a product from

Research to Prototype Item to Production Item Understand and appreciate the time required to complete the

checklist of items that must be considered in taking a Prototype to Production using VERTEK Division: • General items

• Operational

• Maintenance

• System specification issues

• Data requirements

• Ecological and Disposability

• Economic and cost considerations

• Facility requirements

• Training

• Software

• Safety reviews

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From Research to ProductFrom Research to Product

General Items• Is there a real need, and what size is it?

• Are we using the “most appropriate” technology?

• How many suppliers are available for critical technology items?

• What are the risks and uncertainties?

• What are the integrated system considerations?

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From Research to ProductFrom Research to Product Operational Item Considerations

• Has the product’s mission been defined?

• Have the performance requirements been defined?

• What are the technical performance measures?

• What is the projected life cycle?

• What are the environmental requirements in the following areas?▪ Thermal, Humidity, Shock, Noise▪ Storage, in stock and field▪ Transportation and handling

• Have reliability requirements been established?

• Installations procedures (who does)?

• What are serviceability requirements?

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From Research to ProductFrom Research to Product Maintenance Item Considerations

• Have the maintenance levels been defined?

• What are the organizational responsibilities for maintenance?

• Test and support equipment requirements?

• Software for diagnostics available?• What are the spare part requirements?

• What are the repair/re-supply time requirements?

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From Research to ProductFrom Research to Product System Specifications Available?

• Have specifications been established?• Are there any conflicting specifications?• Materials• Performance• Power• Operability• Safety requirements • Reliability (including test and built in test)• Maintainability• Transport• Environmental• System integration (compatibility)• Optional items

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From Research to ProductFrom Research to Product Data Requirements – does product documentation

exist, including:• Circuit diagrams

• Drawing package

• Manuals

• Training materials

• Logistical support documents

• Technical support documents

• Bills of materials

• Assembly instructions

• QA test procedures and review lists

• Are records required and are they subject to audit?

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From Research to ProductFrom Research to Product

Ecological and Disposability Considerations• Are any harmful materials present?

• Are special procedures required at various points in life cycle?

• Are transportation requirements established?

• Labels required?

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From Research to ProductFrom Research to Product Economic Considerations

• Estimated material costs available?

• Estimated pricing complete?

• Market analysis/marketing plan complete?

• Have all costs been considered over life cycle?▪ Variable▪ Fixed▪ Escalation▪ Shipping▪ Learning curves

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From Research to ProductFrom Research to Product

Facility Requirements Defined?• Operational

• Tooling

• Maintenance

• Test

• Training

• Storage

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From Research to ProductFrom Research to Product

Training• Have operational and maintenance personnel requirements

been defined?

• Have training programs been established?

• Is equipment required for training?

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From Research to ProductFrom Research to Product Software

• Have software requirements been defined?

• Has software been documented?

• Licensing considerations?

• Has software been tested and verified on operational units?

• Is maintenance software required?

Safety Review• Have all product reviews been conducted and documented?

• Have all facility reviews been conducted and documented?

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Prototype to ProductionPrototype to Production Engineering Team develops and builds a prototype that

meets a set of specifications mandated by the customer Engineering delivers the prototype to the Production

Team. They also provide:• Rough Bill of Materials (BOM) with vendor information (i.e.

what has to be procured?)

• All schematics (hardware, boards, etc.)

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Prototype to Production ProcessPrototype to Production Process VERTEK Engineering and Production Teams conduct

kick-off meeting to begin technology transfer and documentation process, including final Bill of Materials and drawings • At VERTEK, the Program Manager is in charge of both

Prototype development and production of final product

• The PM assigns a Task PM who is in charge of developing and building the Prototype ▪ The Task PM (AKA: Technical Lead, Task Lead, Control Account

Manager)▪ Has budgetary and technical responsibility for the

R&D effort that ends in prototype delivery and

acceptance by the customer

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Prototype to ProductionPrototype to Production Prototype is considered the baseline product

• All changes made from this point forward are completed via an approved Engineering Change Request/Engineering Change Notice (ECR/ECN) process

• Both the PM and Technical Lead must sign off on all ECRs and ECNs

• The PM evaluates ECR impact to overall program (cost, schedule, fleet configuration)

• Technical Lead evaluates ECR for technical

impact to product and assures product

continues to meet technical specifications

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Prototype to ProductionPrototype to Production

Production evaluates prototype for:• Manufacturability

• Vendor’s qualified

• Scheduling production run

• Personnel requirements

• Equipment/Fabrication requirements

• ID QC points along production

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Prototype to ProductionPrototype to Production

Procurement of components begins and Work Orders are released • PM and Team Leader validate vendor products

• QA Department performs incoming inspection of key vendor parts (PCB, power supplies, etc.)

• All manufacturing, electrical, fabrication and final assembly is completed

• Final QA is performed

• Product is prepared for shipment

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Wrong Way Wrong Way to Do Itto Do It

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Right Way Right Way to Do Itto Do It

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SummarySummary Thorough preplanning is required to take a product from

Research to Prototype Item to Production Item You must engage VERTEK Division early – before the

proposal phase – to ensure a great product for customer and ARA

VERTEK staff always VERTEK staff always available for your available for your

consultationconsultation