NPD-新产品开发控制-课件.ppt

1、NPD-新产品开发控制-PPT课件為何需要新產品開發與流程為何需要新產品開發與流程?新產品開發是什麼新產品開發是什麼?一個團體根據需要一個團體根據需要,訂定計劃訂定計劃,組織人員組織人員,開發設計與驗證樣品開發設計與驗證樣品,並使並使之能大量複製與販售之過程稱之新產品開發流程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為何需要新產品開發?一個以服務產生營利之團體一個以服務產生營利之團體,為使之利潤來源能持續不斷為使之利潤來源能持續不斷,必需在必需在 原有產品利潤降低或開拓新事業領域時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進行新產品開發以維持適當利潤使團體存

2、活當利潤使團體存活.新產品開發風險新產品開發風險 大量複製代表大量材料與金錢投入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若產品有任何重大瑕疵,將會造將會造成產品退貨成產品退貨,輕者損失商譽賠錢解決輕者損失商譽賠錢解決,嚴重可能使公司經營發生困難嚴重可能使公司經營發生困難降低風險提升利潤降低風險提升利潤 經由適當有效流程控制經由適當有效流程控制,複製經驗複製經驗,確保產品開發品質控管機制確保產品開發品質控管機制,以提以提升量產之品質升量產之品質,減低公司營運風險減低公司營運風險;經由經驗分享經由經驗分享,減少犯錯機會減少犯錯機會,降低降低開發時間開發時間,使產品快速上市使產品快速上市

3、,以取得最佳利潤以取得最佳利潤.PDCA LoopPlan: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)PlanDoCheckAction(Quality/品質品質,Cost/成本成本,Delivery/交期交期 )3Life Cycle of Prod

4、uct市場市場Marketing終止終止End of Life企劃企劃Planning開發設計開發設計Design試作試作/Sample評價評價/Evaluation試產試產Pilot Run量產量產Mass Production4Resource of Development Product Design CapabilityPOWERPublicationProduct EngineeringThermalDesignMechanicalIDBIOSS/WF/WElectronicHardwareReliability TestingCompatibility TestingTesting

5、ProgramTesting FixturePCBLayoutSimulation Pre_LoadManufacturingEMC/Safety5Concept DesignDVTMVTEVT Mass ProductionStartPlanning EVT:Engineer Verification Test ,DVT:Design Verification Test ,MVT:Manufacturing Verification TestProduct Development Control Flow Pass Pass Pass Fail Fail Fail Gating Gating

6、 Gating 開發設計開發設計DevelopmentDesign 樣品製作樣品製作Sample Build樣品評價樣品評價VerificationValidation試產試產Pilot Run NPD NPINPD:New Product Development NPI:New Product Introduction 6NPD/NPI NPI OperationMass ProductionODM ProjectOEM Project NPI OperationNPDOperation NPI:New Product Introduction Focus on a product be p

7、hased 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 Operation7 NPI (New Product Introduction)NPI :A process to make a product be produced,deliver

8、ed to customer or market.Product document transferringPilot RunMass ProductionYield rate improvementTechnical/Quality requirementFailure analysis,reliability test Early Manufacturing Involvement DFM/DFT review&feedbackManufacturing Readiness Review Plan,Tooling,spec.,documentSet up project teamProje

9、ct team listdepends on cooperation modelE.C.M.Prototyping 1,2 Sample making E.C.M.:Engineering Change Management:ECR/ECN 8CustomerrequestPrepare InitiatorCheck Section manager of initiator CirculateRelated DepartmentApprove QRB ChiefReleaseDocument center AgreeReject(if someone disagree)Get approval

10、 from customerrequest for change (material,process)PDM work flowInitiator USI internal related dept.ImplementECR/ECN in PDM 91.2.3.21+ChaptersMM*/Site5 BooksQualityManualFunction Procedures&Product InstructionsIndividual Product spec.,Drawing,etc.(大QM)(500 q)T.P.D.OFProductMaterialMethod(Process)Mac

11、hineBOMDrawingSpec.Instruction過期或不適用資料 T.P.D.RelatedWithin Dept.Cross Dept.Cross FunctionNew Requirement of:Y2K International Standards USI Global StructureSOM*/Dept.40 Books10+chaptersTPD in Quality System Structure Date:Apr.20,2000PlanDQAMQAVQASQATQA5 Milestone40 TaskGoal/ProcessSPCMCBManagement M

12、anual:Updated and globalized QM+Gen.etc.(ADM/FD/MIS/Supporting Groups)Revise UpgradeMM(CorporateMM(Business/SitesSOM/Division or dept.TPD,ECN,Reports,etc.per product type.(0)(1)(2)(3)(4)(5)(6)(7)1999 2000 Standard for International and Global(8)TQATQMINTERNALCEGEEXTERNALFEEDBACK/INTERNALFOLLOW UPTWH

13、ead Quarter.EXT.CUSTOMEROversea SiteRD/PM/P SITE INTERNAL ECNECR.CI.FOLLOW UP CI/ECN.Procedure,T.P.D,ECR,CI&ECN FLOWHQ DCSITE DCStandardization ImplementationSITE QRB/DCQRBDCPMMM/TPDSOM10NPI TPD Documentation Coding Number文件名稱單位Coding Number文件名稱單位10 SpecificationPE/CE31 MOITest MOI(T1)TE11 Cosmatic

14、Inspection SpecCosmatic Inspection SpecPEICT Test Coverage(T9)TE12 Parts Programming SpecParts Programming SpecParts Programming SpecPEPackaging Instruction P2RD/MD13 Product SpecProduct SpecProduct SpecPESMT MOI(P1)ME20 DrawingPEASM MOI(P3)MEGerber FilePE32 Rep air GuideRep air GuideRepair GuidePEC

15、omponent Placement ListPE33 Operation ManualOperation ManualOperation ManualAllPCB CAD FilePE40 PlanQA Quality Control PlanQAPCB Panel DrawingME (M/B Quality Plan with IAT)22 Board SchemeticBoard SchemeticPE (BOX Quality Plan with CSA)Feeder ListEQ50 SoftwareBar Code Parts Verification systemEQReflo

16、w Oven Profile ParameterMESYS Mfg.Test ProgramTEPrinting ParameterMEPreload SoftwarePEWave Solder ParameterMEIAT Test ProgramQABGA IC Rework Profile Parameter ME51 BIOS51 BIOSBIOS CodePEUpg rade ListPE52 ICT Test ProgramICT Test ProgramTEError Code ListPE53 FCT Test ProgramFCT Test ProgramTEDifferen

17、ce ListPE54 AOI ProgramAOI ProgramTEHead Code ListPE55 P&P ProgramP&P ProgramEQS/N ListPE56 5D X Ray5D X RayTETest Code ListPE60 Record30 Instruction21 PCB CAD Data11Concept DesignDVTMVTEVT Mass ProductionStartPlanning EVT:Engineer Verification Test ,DVT:Design Verification Test ,MVT:Manufacturing V

18、erification Test Pass Pass Pass Fail Fail Fail Gating Gating Gating 開發設計開發設計DevelopmentDesign 樣品製作樣品製作Sample Build樣品評價樣品評價VerificationValidation試產試產Pilot Run NPD NPINPD:New Product Development NPI:New Product Introduction Product Development Control Flow12What is EVT/DVT/MVT?Purpose:Increase Product

19、 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

20、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 sa

21、mple quantity,conduct all design test item to do verification to ensure product design readiness .13 MVT:Manufacturing Readiness Verification Test -Manufacturing quality level sample -Pilot run with small quantity manufacturing to come out optimization parameter for mass production -Conduct manufact

22、uring 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?14 Planning Requirement of Product Technology Feasibility,Bu

23、siness 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 15 Team member and ResponsibilityBU HeadPM(Project Manager)H/W(Hardware De

24、sign)S/W(Software Design)MD(Mechanical Design)PowerPCB Layout EMCHomologationSafety Logo Certification Hardware FunctionTestCompatibility Function TestStability/Reliability TestMechanical TestPE(Product Engineer)Manufacturing ProcessManufacturing Testing Manufacturing Equipment Manufacturing QA PM:O

25、wner to coordinate NPD operation PE:Owner to coordinate NPI operation NPD NPI Team list to have project member assignment from related function team 16Main Flow of Development Specification(H/W,Mechanical,S/W,Regulation )Schedule,Cost Product Design(Hardware)(Mechanical)(Software)Design Qualificatio

26、n Assurance(DQA)Design for Manufacturing(DFM)Design for Testing(DFT)Design for AvailabilityServiceability(DFA,DFS)Mass Production ManufacturingQualification Assurance(MQA)17Design Activity FlowDesign Design ReviewDesign Check List Simulation SpecificationRegulation Requirement EMCSafety ThermalDesig

27、nCheck ListDFMDFTDFADFSEMCSafety ThermalKnow How Experience Approved18Design QualificationTest Plan SpecificationDesign Qualification Testing Bug Alerting and TrackingDesign Exit Gating Test Report19Design Qualification Plan for Server Design Qualification Plan for Server EVT 1.Hardware Function Tes

28、t 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 PredictionDVT 1.Hardware Funct

29、ion 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 Te

30、st 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 u

31、p 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 20Category of Design QualificationProduct SpecificationEnviro

32、nment StressRegulation/CertificationLife 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

33、.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.Manufacturabil

34、ity analysis 2.Test Cover Analysis 21DFM(Design For Manufacturing)Quality,Cost RequirementUSI 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,

35、Time To Volume RequirementProcess Target Special Fixture or Tooling Preparing Enough Design Margin and Tolerance22DFT(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 Ru

36、le,Check List,Lesson Learn)Bug Alerting and Tracking RequirementProcess Target Test Code,Special Fixture or Tooling Preparing23DFA(Design For Availability)Supply Risk Analysis Early Involvement Supplier ManagementBOM(Bill Of Material)Cost Effective,Time To Volume RequirementProcess Target Right Part

37、s Selection Quality,Cost,Availability Requirement24DFS(Design For Serviceability)Design Review(Design Rule,Check List,Lesson Learn)Service Cost Analysis Early Involvement FRU Management PE Close Loop RecordHighest Customer Service SatisfactionRequirementProcess TargetEasy Handling,Lowest Service Cos

38、tOn Time Service RequirementBug Alerting and Tracking25 Development DocumentationFG BOMProject Folder MVT 32A2 Level BOMA1 Level BOMM/B H/W Design Output MVT 32S/W Design Output MVT 32BIOS Design Output DVT 21Mechanical Design Output MVT 32Product Folder AMOI MVT 31 BIOS MVT 32Schematic DVT 23PCB La

39、yout MVT 31 Document BOM Material BOM 26Specification requirement Design Design Output Review Sample fabrication Sample Qualification Test Report Design phase gating Bug tracking Sample debug and solution StartNext PhaseAction List Development Control operation Periodic Design Review27PDM Bug Tracki

40、ng WorkflowOpenWorkAssignConfirmCloseAdd a defect.Fixing the defect RejectFail.Verify the fix&chooses either Pass or FailActionPass*DebugVerifyFailYesCancel (Any Time)By Supervisor or Originator ActionNo(A)(E)(E,D,C)(E)(C)(B)(B)28Solution Factor Coding Solution Description ASolution introduced indus

41、trially by-YesBug 對策經驗證具量產能力BSolution introduced industrially by-No,Evaluated by-YesBug 對策經驗證有效,尚未具量產能力CEvaluated by-No,Solution know-YesBug 已有對策,對策尚未能驗證,DSolution know-No,Cause know-YesBug 尚無對策,已知因由ECause known-NoBug 尚不知因由29Severity level of Problem Coding Development consideration1 1(Critical prob

42、lem,user cannot continue.)Unable to proceed with major portion of test ordevelopment.AND/OR Defect causes a major checkpointto slip day-by-day,AND/OR the customer is halted.Immediate fix is needed.2 2(Serious problem,user severely restricted.)Test or customer is severely restricted due to a defecten

43、countered for which there is no acceptable workaround.3 3(Problem,user not severely restricted.)Able to proceed with limited function which is not crucial totest or development.Either the defect is serious but anacceptable circumvention exists,or the defect is not aserious4 4(Problem,slight hindranc

44、e for user.)No immediate impact to test or customer.Cosmeticproblem with no functional impact.30Design 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 judg

45、e 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.31 Lesson Learn Operation FlowProject DevelopmentEVT/DVT/MVT StartDesign Guide Check List Bug Tracking List Mass Production Less

46、on 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.C.tw33