New Product Introductions - Expertise provided from VP of Engineering, VP of Operations, and Contract Manufacturing perspectives
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Product Realization Group
Lunch SeriesLunch Series
New Product Introduction –Launching Success!Launching Success!
….new product introduction processes and war stories
Mi h l KMichael KeerFounder and CEOProduct Realization Groupmkeer@productrealizationgroup com
VP of Engineering: Kevin Rowett, Violin MemoryK i h f lfill d i i i l i l di Kevin has fulfilled various engineering roles including MTS, CTO, Director of Engineering, and VP of engineering, at a wide range of Silicon Valley companies including Tandem Computers, Cisco p g p ,Systems, Force10 Networks, Blue Coat (then Cacheflow), Gigafin, and Seamicro. He has built and led several successful engineering teams, and holds more than a dozen patentsmore than a dozen patents.
VP of Operations: Tim Miller, Trilliant NetworksTim has over twenty-five years of success in a broad Tim has over twenty five years of success in a broad range of leadership positions as a U.S. Army officer and operations and manufacturing management positions at both Fortune 500 and start-up companies including Texas Instruments Dell NEC Terayon and
including Texas Instruments, Dell, NEC, Terayon and Aperto.
Introductions
EMS: Murad Kurwa: VP of Eng., Flextronics InternationalMurad has over twenty-five years in industries related to Electronic Products, Semiconductor Devices and Material Science, with seventeen in EMS fulfilling , gManagement, Engineering, Development, Test, and Operations roles. Murad has an MBA in Finance & BS Chemical Engineering, along with over 20 publications. g g, g p
When does a product enter an NPI process or program? When does a product enter an NPI process or program?
No easy answer here. Often, it becomes obvious.
Requires strong cooperation between VP of Engineering and VP of Operations.
Portions happen early on – major component selection, PCB fabricator selection Others happen as first protosPCB fabricator selection. Others happen as first protoscome alive. Still more as the beta units start rolling out.
Choices made in engineering affect a product for a long Choices made in engineering affect a product for a long time – a solid NPI program makes sure manufacturing can live with those choices.
Large, Tier 1 CMs have a flow and recipe for fabrication and assembly Need to learn this – NPI is the pathand assembly. Need to learn this NPI is the path.
I once let an analog engineer bypass my NPI and a PCB fabricators NPI, working directly with the plant –never were able to fabricate that PCB in volume
Operations responsibility – QCD p p y Q• Quality & Reliability• Cost• Delivery• DeliveryDesign characteristics that enable operations to be successful – DFx:
M f t bilit• Manufacturability• Testability• Quality (yield, variability, cust. expectations)Q y (y , y, p )• Reliability• Availability (time-to-market, lead-time) • Cost
Early stages (Justification, Feasibility)Early stages (Justification, Feasibility)• Strategic component/supplier selection Single Source Approval Process Single Source Approval Process
Early (Justification Feasibility)Early (Justification, Feasibility)• DFM guidelines• Participation in decision making p g• Determination of inventory strategy (build-
to-order, build-to-forecast, or something in between)between)
Early (Justification, Feasibility)y ( y)• DFT guidelines
Mid stages (Development) • DFT reviewDFT review• Concurrent test development • Test of prototypes• Test time assumptions (labor capital cost)Test time assumptions (labor, capital cost)• Yield analysis and feedback
Late stages (Beta, Pilot)Final DFT review• Final DFT review
• Validation of yield assumptions• Cost reduction (labor) feedback
Early involvement and Early involvement and implementation of feedback from Operations will result in lower cost pproduct• Capital equipment cost• Material cost• Freight cost• Labor cost• Test labor cost
• In outsourced manufacturing • In outsourced manufacturing, EMS/CM has expertise & capability that Operations team may not have
• A good manufacturing partner (EMS/CM) involved early in the process and throughout the process process and throughout the process can add significant value
• Consider tradeoffs• Ownership of Fixtures, etc.• Transferability