NPD新产品开发控制.ppt

New Product DevelopmentNPD(新產品開發流程),陳堅慈(Fred Chen),June 14-2002,2,為何需要新產品開發與流程?,新產品開發是什麼?一個團體根據需要,訂定計劃,組織人員,開發設計與驗證樣品,並使之能大量複製與販售之過程稱之新產品開發流程.為何需要新產品開發?一個以服務產生營利之團體,為使之利潤來源能持續不斷,必需在 原有產品利潤降低或開拓新事業領域時,進行新產品開發以維持適當利潤使團體存活.新產品開發風險 大量複製代表大量材料與金錢投入,若產品有任何重大瑕疵,將會造成產品退貨,輕者損失商譽賠錢解決,嚴重可能使公司經營發生困難降低風險提升利潤 經由適當有效流程控制,複製經驗,確保產品開發品質控管機制,以提升量產之品質,減低公司營運風險;經由經驗分享,減少犯錯機會,降低開發時間,使產品快速上市,以取得最佳利潤.,3,PDCA Loop,Plan:To have a plan,(What it is,How and When to do,How to check)Do:Follow plan to do Check:Follow plan to do checking Action:To assess the effectiveness of result with plan,PDCA(Plan/Do/Check/Action),Plan,Do,Check,Action,(Quality/品質,Cost/成本,Delivery/交期),4,Life Cycle of Product,市場Marketing,終止End of Life,企劃Planning,開發設計Design,試作/Sample評價/Evaluation,試產Pilot Run,量產Mass Production,5,Resource of Development,Product Design Capability,POWER,Publication,Product Engineering,ThermalDesign,MechanicalID,BIOSS/WF/W,ElectronicHardware,Reliability Testing,Compatibility Testing,TestingProgram,Testing Fixture,PCBLayoutSimulation,Pre_Load,Manufacturing,EMC/Safety,6,Concept Design,DVT,MVT,EVT,Mass Production,Start,Planning,EVT:Engineer Verification Test,DVT:Design Verification Test,MVT:Manufacturing Verification Test,Product Development Control Flow,Pass,Pass,Pass,Fail,Fail,Fail,Gating,Gating,Gating,開發設計DevelopmentDesign,樣品製作Sample Build樣品評價VerificationValidation,試產Pilot Run,NPD,NPI,NPD:New Product Development NPI:New Product Introduction,7,NPD/NPI,NPI Operation,Mass Production,ODM Project,OEM Project,NPI Operation,NPDOperation,NPI:New Product Introduction Focus on a product be phased in manufacturing related activities.NPD:New Product Development Except the NPI activities,It also included product design and design verification and validation related activities.,Pass,Fail,Gating,NPI Operation,8,NPI(New Product Introduction),NPI:A process to make a product be produced,delivered to customer or market.,Product document transferring,Pilot Run,Mass Production,Yield rate improvement,Technical/Quality requirement,Failure analysis,reliability test,Early Manufacturing Involvement,DFM/DFT review&feedback,Manufacturing Readiness Review,Plan,Tooling,spec.,document,Set up project team,Project team list,depends on cooperation model,E.C.M.,Prototyping 1,2,Sample making,E.C.M.:Engineering Change Management:ECR/ECN,9,ECR/ECN in PDM,10,QualityManual,Function Procedures&Product Instructions,Individual Product spec.,Drawing,etc.,(大QM),(500 q),Current Structures,T.P.D.,OF,Product,Material,Method(Process),Machine,BOM,Drawing,Spec.,Instruction,T.P.D.Related,Within Dept.,Cross Dept.Cross Function,New Structures,SOM*/Dept.40 Books10+chapters,TPD in Quality System Structure,Date:Apr.20,2000,Management Manual:Updated and globalized QM+Gen.etc.(ADM/FD/MIS/Supporting Groups),Revise Upgrade,(0),(1),(2),(3),(4),(5),(6),(7),1999 2000 Standard for International and Global,(8),TQA,TQM,Best Class,INTERNALCEGE,EXTERNAL,FEEDBACK/INTERNAL,FOLLOW UP,EXT.CUSTOMER,ECN,ECR.,CI.,FOLLOW UP CI/ECN.,Procedure,T.P.D,ECR,CI&ECN FLOW,HQ DC,SITE DC,Standardization Implementation,SITE QRB/DC,QRB,DC,PM,MM/TPD,SOM,TPD:Technical Product Document,11,NPI TPD Documentation,12,Concept Design,DVT,MVT,EVT,Mass Production,Start,Planning,EVT:Engineer Verification Test,DVT:Design Verification Test,MVT:Manufacturing Verification Test,Pass,Pass,Pass,Fail,Fail,Fail,Gating,Gating,Gating,開發設計DevelopmentDesign,樣品製作Sample Build樣品評價VerificationValidation,試產Pilot Run,NPD,NPI,NPD:New Product Development NPI:New Product Introduction,Product Development Control Flow,13,What is EVT/DVT/MVT?,Purpose:Increase Product Development Quality Reduce Risk of Development and Cost.,EVT:Engineering Sample Verification Test-Early engineering sample meet product specification requirement without severity bugs,the sample may be made by mechanical mockup,earlier version hardware and software.-With small sample quantity,less test resource involvement,Key and critical test items to verify the sample.DVT:Design Readiness Verification Test-Design mature engineering sample meet product specification requirement without bugs,the sample should be tooling mechanical parts with near mature hardware and software.-With enough sample quantity,conduct all design test item to do verification to ensure product design readiness.,14,MVT:Manufacturing Readiness Verification Test-Manufacturing quality level sample-Pilot run with small quantity manufacturing to come out optimization parameter for mass production-Conduct manufacturing point view verification with quantitative sample to test product early life performance-Prepare parts for after service requirement-Got related regulation and certification for product-Ready for mass production,What is EVT/DVT/MVT?,15,Planning,Requirement of Product,Technology Feasibility,Business Feasibility,Project Plan,Specification(H/W,ID/Mechanical,S/W,Regulation)Schedule Statement Of Work(Scope Of Work)PM,Team List Cost Sample plan Budget,Customer Product Marketing,Internal Capability External Supporting,16,Team member and Responsibility,BU Head,PM(Project Manager),H/W(Hardware Design),S/W(Software Design),MD(Mechanical Design),PowerPCB Layout,EMCHomologation,Safety,Logo Certification,Hardware FunctionTest,Compatibility Function Test,Stability/Reliability Test,Mechanical Test,PE(Product Engineer),Manufacturing Process,Manufacturing Testing,Manufacturing Equipment,Manufacturing QA,PM:Owner to coordinate NPD operation PE:Owner to coordinate NPI operation,NPD,NPI,Team list to have project member assignment from related function team,17,Main Flow of Development,Specification(H/W,Mechanical,S/W,Regulation),Schedule,Cost,Product Design(Hardware)(Mechanical)(Software),Design Qualification Assurance(DQA),Design for Manufacturing(DFM),Design for Testing(DFT),Design for AvailabilityServiceability(DFA,DFS),Mass Production,ManufacturingQualification Assurance(MQA),18,Design Activity Flow,Design,Design Review,Design Check List,Simulation,Specification,Regulation Requirement,EMCSafety Thermal,DesignCheck List,DFMDFT,DFADFS,EMCSafety Thermal,Know How Experience,Approved,19,Design Qualification,Test Plan,Specification,Design Qualification Testing,Bug Alerting and Tracking,Design Exit Gating,Test Report,20,Design Qualification Plan for Server,EVT 1.Hardware Function Test 2.BIOS Function Test 3.Intensive Test 4.Windows ME Function Test 5.Win NT/2000/XP Server Function Test 6.Server Management Test7.Power On/Off Boot up Test 8.Design Margin Test 9.Signal Quality Analysis 10.EMC Test 11.Thermal Test 12.Manufacturability analysis 13.MTBF Prediction,DVT 1.Hardware Function Test 2.BIOS Function Test 3.Intensive Test 4.Win NT/2000/XP Server Function Test 5.Server Management Test6.Server Stress Test 7.Sever Logo Pre Test 8.S/W,H/W Compatibility Test 9.Power On/Off Boot up Test 10.Design Margin Test 11.Signal Quality Analysis 12.EMC Test 13.Thermal Test 14.Acoustic Test 15.Vibration Test 16.Drop Test 17.Safety Test 18.Manufacturability analysis,MVT 1.Hardware Function Test 2.BIOS Function Test 3.Intensive Test 4.Win NT/2000/XP Server Function Test5.Server Management Test6.Server Stress Test 7.Sever Logo Pre Test 8.S/W,H/W Compatibility Test 9.Power On/Off Boot up Test 10.Design Margin Test 11.Signal Quality Analysis 12.EMC Test 13.Thermal Test 14.Acoustic Test 15.Safety Test 16.Manufacturability analysis 17.Server Logo Submission 18.EMC Regulation Certification 19.ELP(Early Life Performance)Test,21,Category of Design Qualification,Product Specification,Environment Stress,Regulation/Certification,Life Performance,1.Hardware Function Test 2.BIOS Function Test 3.Compatibility Test 4.OS Function Test 5.Signal Quality Analysis 6.Mechanical Thermal Test,1.ELP(Early Life Performance)Test 2.MTBF Test,1.Power On/Off Boot up Test 2.Design Margin Test 3.H/T/B Test 4.Thermal Cycling Test 5.Thermal Shock Test 6.Acoustic Test 7.Vibration Test 8.Mechanical Shock Test 9.Drop Test,1.EMC Regulation Certification 2.Safety Regulation Certification 3.WHQL Logo Certification 4.Green PC Certification 5.Wi-Fi Certification 6.BQB Certification,Manufacturing,1.Manufacturability analysis 2.Test Cover Analysis,22,DFM(Design For Manufacturing),Quality,Cost Requirement,USI and Supplier Process Requirement,Easy Fabrication,Assembly,Design Review(Design Rule,Check List,Lesson Learn),Early Involvement,Bug Alerting and Tracking,Shortest Cycle Time,Zero Failure Rate,Cost Effective,Time To Volume,Requirement,Process,Target,Special Fixture or Tooling Preparing,Enough Design Margin and Tolerance,23,DFT(Design For Testing),Quality,Cost Requirement,Easy Testing,Enough Coverage,100%Test Coverage,Early Involvement,Shortest Cycle Time,Cost Effective,Time To Volume,Design Review(Design Rule,Check List,Lesson Learn),Bug Alerting and Tracking,Requirement,Process,Target,Test Code,Special Fixture or Tooling Preparing,24,DFA(Design For Availability),Supply Risk Analysis,Early Involvement,Supplier Management,BOM(Bill Of Material),Cost Effective,Time To Volume,Requirement,Process,Target,Right Parts Selection,Quality,Cost,Availability Requirement,25,DFS(Design For Serviceability),Design Review(Design Rule,Check List,Lesson Learn),Service Cost Analysis,Early Involvement,FRU Management,PE Close Loop Record,Highest Customer Service Satisfaction,Requirement,Process,Target,Easy Handling,Lowest Service Cost,On Time Service Requirement,Bug Alerting and Tracking,26,Development Documentation,FG BOM,Project Folder MVT 32,A2 Level BOM,A1 Level BOM,M/B H/W Design Output MVT 32,S/W Design Output MVT 32,BIOS Design Output DVT 21,Mechanical Design Output MVT 32,Product Folder A,MOI MVT 31,BIOS MVT 32,Schematic DVT 23,PCB Layout MVT 31,Document BOM,Material BOM,27,Specification requirement,Design,Design Output Review,Sample fabrication,Sample Qualification,Test Report,Design phase gating,Bug tracking,Sample debug and solution,Start,Next Phase,Action List,Development Control operation,Periodic Design Review,28,PDM Bug Tracking Workflow,Open,Work,Assign,Confirm,Close,Add a defect,.Fixing the defect,Reject,Fail,.Verify the fix&chooses either Pass or Fail,Action,Pass,*Debug,Verify,Fail,Yes,Cancel,(Any Time)By Supervisor or Originator,Action,No,(A),(E),(E,D,C),(E),(C),(B),(B),29,Solution Factor,30,Severity level of Problem,31,Design Phase Exiting,Base on test plan to do Design Qualification Assurance Bug tracking management Base on the bug severity and solution factor to judge phase exiting Base on the product maturity to judge to phase in mass production or lunch in market USI own product exiting control by QA and related Customer own product,maturity review by QA and got exiting from Customer.,32,Lesson Learn Operation Flow,Project DevelopmentEVT/DVT/MVT,Start,Design Guide,Check List,Bug Tracking List,Mass Production,Lesson Learn,Design stage,design team follow design guide or rule to conduct design.Design teams base on related check list to review and qualify design output to avoid same problem happen.,Input bug to bug tracking system to conduct effective debugging,Conducted lesson learn when project close or vital failure occur,base on bug list record and key experience to feedback into design guide,check list to avoid making same failure and amplify advancement.,After Service,PE Close loop,Collected after service PE close loop input and feedback into design activity.,Close,.tw,