新產(chǎn)品導入程序管理專題培訓(英文版)課件

NPIPROGRAMMANAGEMENT

新產(chǎn)品導入程序管理NPIPROGRAMMANAGEMENT1INDEXIntroductionforNPITheFocusforNPIWhatiscustomer’smostconcernduringNPIprocess?NPIProcessINDEXIntroductionforNPITheF2NPIisbecomingmoreandmoreimportantinmostmanufacturingcompanies.Itisthefirststeptowincustomerconfidenceonbothproductioncapabilityandbusinessmanagement.IntroductionFullNameofNPI:NewProductIntroductionCONTENTNPIisbecomingmoreandmore3NPIlocatesbetweendesignandmassproductionanditisaverifyingprocesstoproductdesignandproduction.NPIlocatesbetweendesignand4HowtogetprofitfromtheNPIbusiness;TheFocusforNPIStandingasmanufacturingserviceprovider,weneedfocusonfollowings:HowtomanagetheNPIbusiness;HowtogetprofitfromtheNPI5HowtocomeoutaproperNPIreporttocustomertogetcustomerapproval;HowtotransfertheNPItofactorytoimplementmassproductionsmoothly;HowtocomeoutaproperNPIr6Forthesupplier:a>Quality

b>Capacity

Whatiscustomer’smostconcernduring

NPIprocess?Forthesupplier:7Fortheproduct:

a>Enoughtrainingtooperatorsandengineersb>Productrequirementareclearandimplementedsolidlyc>Processsetupadequatelyd>Processevaluationisready

---------ThepracticeandlessonlearntinNPIphasearemostimportantascustomerisprefertosolveallproblemswhicharerelatedtodesignandsystemfaultatthisphase,notmassproductionphase.Fortheproduct:8

Pre-studyPhaseNPIProcess

PlanningPhase

ExecutionPhase

Trial-runPhase

Ramp-upPhase

TransferPhasePre-studyPhaseNPIProcessPl9

Pre-studyPhase----------Salesmanagerwillcallrelatedpeopletoreviewthesalesoffer,forecast,projectbudgetandagreement.Atthesametime,productengineersneedtoaskfortheinformationssuchasproductspecificsandproductionrequirementfromPMorcustomertoknowtheprouctinadvance.Pre-studyPhase----------Sale10

PlanningPhase

-----------Thisphaseisveryimportanttowholeprogram.PMshouldhaveadetailedlisttoreviewonebyonetoensureallinformationarereadyandallplanhaveresponsiblepeopleanddeadline.ITEMRELATEDPLANSaProjectmilestonebProjectorganizationcInvestmentplandFacilityplaneMaterialmanagementplanfQualityplangManufacturingplanhRiskmanagementplaniECR/ECOplanjCPManalysisandback-upsolutionconsiderationPlanningPhase--------11a>Projectmilestone(Schedule)

b>Projectorganization(Team)-----ProcessEngineer/SMTEngineer/DiagnosticEngineer/QualityEngineer/ProgramManager/Sales/Buyer/Planner/PDM(productdocumentmanager)/Financeetc.

c>Investmentplan-----PMorhigherhierarchytodefinetheinvestment.Theinvestmentincludesequipmentcost,tooling&jig&fixturecost,trainingcostandrenovationcost.Mostcosthasbeenputintoquotationandnowweneedcontrolitbyitems.a>Projectmilestone(Schedule)12d>Facilityplan.PMshouldcallproductionmanager,WHmanager,facilitymanagertodefinethelocation:-----whichSMTlinecanbeadequateuse?-----wheretoallocatetheproductionline?-----wheretostorethefinishedgoods?

d>Facilityplan.13e>Materialmanagementplan.-----WeneedMaterialManagertodiscussthepurchasingplananddeliveryplanifconsignedmaterialthereis.-----Thisplanisveryserioustomakesurethereisnomaterialshortage.-----Shortageisveryeasyoccurredonthreecases:

singlesourceDOS(daysofsupply)toolong

badBOMusage

Forthiscase,wecanusesafestocktocontrol.

f>Qualityplan.-----Qualitydept.shouldprovidequalitycontrolplan,sub-suppliermanagementplan,FMEA,environmentreport(ifapplicable).e>Materialmanagementp14g>Manufacturingplan:-----Productionmanagershouldreportthemanpowerallocationandmakethetrainingplantooperators.-----IEshouldfinishedthelayoutplanandstandardtimecalculation,basedonthevolume,shiftarrangement,operatorquantity,linelayout,tooling&equipmentbalance,technicalpeoplesupport.-----TestengineershouldalsofeedbacktherunningstatustoPM.

h>Riskmanagementplan:-----Notallpotentialproblemswouldoccur,butifoccur,someplanandworkmaygoingto“death”.

g>Manufacturingplan:15i>ECR/ECOplan:-----PDMandproductengineershouldcontrolthisplan.PMhavetoconcernaboutoncetheengineeringchangewouldcausecostchange.So,todefineanECR/ECOhandlingprocedureandcostcontrolprocessarenecessary.

j>CPManalysisandback-upsolutionconsideration:

-----CPM:CriticalPathMethod

-----Whenallplanswereready,PMshouldhaveareviewtoalltheseactivitiesasaby-stagecome-out.Wetitlethereviewmeetingas“planningreview”or“start-upreview”.Thepurposeistomakesureallactivitiesareundercontrolandrunningaswhatweexpected.

i>ECR/ECOplan:16

-----FollowingherearesomeItemswhicharecriticalandneedhighattentioninthereviewmeeting:NO.CriticalItemsaGeneralInformationbSupplychainmanagementcProductionlinesettingdQualityeOtherproblem-----Followinghereare17GeneralInformation:-----customermilestone-----capacity-----volume-----dedicatedprojectpersonnelSupplyChainManagement:-----thefocusisonprocurementmanagementandcomponentcoding(orBOMcoding).Beforethemeeting,MaterialpeopleshouldreviewtheBOMandcheckoutwhichonesarecriticalcomponents.Thecriticalcomponentmainlymeanssupplier-controlledmarketand/orhigh-valueuniquecomponent.

GeneralInformation:18ProductionLineSetting:----SMTpackage(Gerber,X-Y,PCNdrawing)----assemblyprocess----packingrequirement(domesticandexport)----traceability----testingsoftwareandhardware----toolingpreparation----deliverymethod----cosmeticspecificationandcheckingmethod----plantlayout----operatortrainingandshiftarrangement

ProductionLineSetting:19Quality:-----controlplanandflowchart,-----environmentaudit-----processaudit-----GR&R-----goldensample-----trialrunpremises-----processqualificationrequirementOtherProblem:-----finance-----logistics-----securityQuality:20

ExecutionphaseAssoonascustomergivesgosignal,theNPIispromotedinto“executivephase”andachecklistneedtobemade.NO.CheckItemaAVLandBOMbProductioncPackingDesignandInstructiondQualitydocumentseCustomerSpecificationandGoldenSamplefCapitalExpenditureExecutionphaseNO.CheckItem21

Productiondocuments:a>

ProcessFlow-chartb>SOP(orMI/WI)c>TestInstructiond>FinalInspectionInstructione>PackingDesignandInstruction.a>PFMEAb>ControlPlanc>GR&Rd>CapabilityStudye>PQPPlan.

Productiondocuments:

AVL(AML)andBOM:Productiondocuments:a>Proc22

CustomerSpecification&GoldenSample(ifapplicable):a>

Makesurethelatestqualityandproductspecificationwasgot,andrenewaloftestsoftware.b>Qualityengineershouldtransferthespecificationintointernalformat.c>Testingengineershouldhaveasoftwareupgradelist.d>FinalInspectionInstruction.e>Differentdocumentversionmaybeappliedtodifferentproductversion.

CapEx:

-----CheckthatapprovedCapExisavailable.

CustomerSpecification&Gold23

Trial-runPhase-----CustomerreleasedformalPO#andconfirmedprice,westarttrialrun.Theoutputistrialrunreportfromengineerteam.Theresultistrialrunsampleapprovedbycustomerandgiveramp-upsignal.-----ThetrialrunreportshouldcovertheprocessesfromSMTtopackingandshipment.Weshouldraiseactionplanforallcriticalproblemsandpotentialsnecessarily.Aftertrialrun,samplewouldbesenttocustomerbasedonrequest.

Trial-runPhase24-----Aftertrialrun,samplewouldbesenttocustomerbasedonrequest.-----Inmostcases,thewholeNPIcanbelengthenedorshortenedduetomanyfactors,anditisalsonaturallyhavedirectcorrelationtocustomerdemand.

functionalitycomplexityrequirementpredictedvolume

Thereare4basicfactors:-----Aftertrialrun,samplew25

Ramp-upPhase-----Thetrialrunsamplewasapprovedbycustomerand“go-signal”wasreleased,itmeanswecanmoveto“ramp-upphase”successfully.-----ThisisthefinalphaseforNPI.Wemustcheckwhatislostorneedfurtherimprovementforfactoryproduction.

-----Infact,customerwouldgiveupdatedforecastandMRPplannow.Plannercanmakeproductionschedulebasedonthat.

Ramp-upPhase-----Thetrialr26

TransferPhase-----WhencustomerapprovedtheRamp-upplan,NPIPMhastocallameetingwithfactorysteeringtotransfertheprojectandreporttocustomeraboutthetransfer.-----prepareacompletedNPIreporttofactorymemberstomakethetransfersuccessful.-----KPI(KeyPerformanceIndicators)KPIsaremeasurestoaNPIproject:PMhastoreviewtheactualvstarget.TransferPhase-----Whencusto27PMneedreviewtheactualvstarget.

-----Projecttimeschedule

-----Projectbudget(fromCapExandProcessperformance,e.g.Yield,scraprate,etc)-----Linecapacity

PMneedreviewtheactualvst28DocumentsforKPIs:

CapExandInvestmentplan

-----ProjectManagementDocument

Quotationreport

Projectorganizationandmeeting,necessarypresentationBOM&ECO

Productlog,includingallproductchange

Drawing&Specification

-----ProductInformation

Quotationreport

LayoutandfacilityrequestStandardtimecalculationRamp-upplan

DocumentsforKPIs:29Controlplan,flowchartandPFMEA

-----PQPDocuments:

Quotationreport

Capability&GR&RreportWorkinstructionsSMTdocuments

-----ProcessRequirement:

Assemblydocuments

TestingdocumentTraceabilityrequirementPackingandshippingrequirementOthersControlplan,flowchartandP30THEENDTHEEND31NPIPROGRAMMANAGEMENT

新產(chǎn)品導入程序管理NPIPROGRAMMANAGEMENT32INDEXIntroductionforNPITheFocusforNPIWhatiscustomer’smostconcernduringNPIprocess?NPIProcessINDEXIntroductionforNPITheF33NPIisbecomingmoreandmoreimportantinmostmanufacturingcompanies.Itisthefirststeptowincustomerconfidenceonbothproductioncapabilityandbusinessmanagement.IntroductionFullNameofNPI:NewProductIntroductionCONTENTNPIisbecomingmoreandmore34NPIlocatesbetweendesignandmassproductionanditisaverifyingprocesstoproductdesignandproduction.NPIlocatesbetweendesignand35HowtogetprofitfromtheNPIbusiness;TheFocusforNPIStandingasmanufacturingserviceprovider,weneedfocusonfollowings:HowtomanagetheNPIbusiness;HowtogetprofitfromtheNPI36HowtocomeoutaproperNPIreporttocustomertogetcustomerapproval;HowtotransfertheNPItofactorytoimplementmassproductionsmoothly;HowtocomeoutaproperNPIr37Forthesupplier:a>Quality

b>Capacity

Whatiscustomer’smostconcernduring

NPIprocess?Forthesupplier:38Fortheproduct:

a>Enoughtrainingtooperatorsandengineersb>Productrequirementareclearandimplementedsolidlyc>Processsetupadequatelyd>Processevaluationisready

---------ThepracticeandlessonlearntinNPIphasearemostimportantascustomerisprefertosolveallproblemswhicharerelatedtodesignandsystemfaultatthisphase,notmassproductionphase.Fortheproduct:39

Pre-studyPhaseNPIProcess

PlanningPhase

ExecutionPhase

Trial-runPhase

Ramp-upPhase

TransferPhasePre-studyPhaseNPIProcessPl40

Pre-studyPhase----------Salesmanagerwillcallrelatedpeopletoreviewthesalesoffer,forecast,projectbudgetandagreement.Atthesametime,productengineersneedtoaskfortheinformationssuchasproductspecificsandproductionrequirementfromPMorcustomertoknowtheprouctinadvance.Pre-studyPhase----------Sale41

PlanningPhase

-----------Thisphaseisveryimportanttowholeprogram.PMshouldhaveadetailedlisttoreviewonebyonetoensureallinformationarereadyandallplanhaveresponsiblepeopleanddeadline.ITEMRELATEDPLANSaProjectmilestonebProjectorganizationcInvestmentplandFacilityplaneMaterialmanagementplanfQualityplangManufacturingplanhRiskmanagementplaniECR/ECOplanjCPManalysisandback-upsolutionconsiderationPlanningPhase--------42a>Projectmilestone(Schedule)

b>Projectorganization(Team)-----ProcessEngineer/SMTEngineer/DiagnosticEngineer/QualityEngineer/ProgramManager/Sales/Buyer/Planner/PDM(productdocumentmanager)/Financeetc.

c>Investmentplan-----PMorhigherhierarchytodefinetheinvestment.Theinvestmentincludesequipmentcost,tooling&jig&fixturecost,trainingcostandrenovationcost.Mostcosthasbeenputintoquotationandnowweneedcontrolitbyitems.a>Projectmilestone(Schedule)43d>Facilityplan.PMshouldcallproductionmanager,WHmanager,facilitymanagertodefinethelocation:-----whichSMTlinecanbeadequateuse?-----wheretoallocatetheproductionline?-----wheretostorethefinishedgoods?

d>Facilityplan.44e>Materialmanagementplan.-----WeneedMaterialManagertodiscussthepurchasingplananddeliveryplanifconsignedmaterialthereis.-----Thisplanisveryserioustomakesurethereisnomaterialshortage.-----Shortageisveryeasyoccurredonthreecases:

singlesourceDOS(daysofsupply)toolong

badBOMusage

Forthiscase,wecanusesafestocktocontrol.

f>Qualityplan.-----Qualitydept.shouldprovidequalitycontrolplan,sub-suppliermanagementplan,FMEA,environmentreport(ifapplicable).e>Materialmanagementp45g>Manufacturingplan:-----Productionmanagershouldreportthemanpowerallocationandmakethetrainingplantooperators.-----IEshouldfinishedthelayoutplanandstandardtimecalculation,basedonthevolume,shiftarrangement,operatorquantity,linelayout,tooling&equipmentbalance,technicalpeoplesupport.-----TestengineershouldalsofeedbacktherunningstatustoPM.

h>Riskmanagementplan:-----Notallpotentialproblemswouldoccur,butifoccur,someplanandworkmaygoingto“death”.

g>Manufacturingplan:46i>ECR/ECOplan:-----PDMandproductengineershouldcontrolthisplan.PMhavetoconcernaboutoncetheengineeringchangewouldcausecostchange.So,todefineanECR/ECOhandlingprocedureandcostcontrolprocessarenecessary.

j>CPManalysisandback-upsolutionconsideration:

-----CPM:CriticalPathMethod

-----Whenallplanswereready,PMshouldhaveareviewtoalltheseactivitiesasaby-stagecome-out.Wetitlethereviewmeetingas“planningreview”or“start-upreview”.Thepurposeistomakesureallactivitiesareundercontrolandrunningaswhatweexpected.

i>ECR/ECOplan:47

-----FollowingherearesomeItemswhicharecriticalandneedhighattentioninthereviewmeeting:NO.CriticalItemsaGeneralInformationbSupplychainmanagementcProductionlinesettingdQualityeOtherproblem-----Followinghereare48GeneralInformation:-----customermilestone-----capacity-----volume-----dedicatedprojectpersonnelSupplyChainManagement:-----thefocusisonprocurementmanagementandcomponentcoding(orBOMcoding).Beforethemeeting,MaterialpeopleshouldreviewtheBOMandcheckoutwhichonesarecriticalcomponents.Thecriticalcomponentmainlymeanssupplier-controlledmarketand/orhigh-valueuniquecomponent.

GeneralInformation:49ProductionLineSetting:----SMTpackage(Gerber,X-Y,PCNdrawing)----assemblyprocess----packingrequirement(domesticandexport)----traceability----testingsoftwareandhardware----toolingpreparation----deliverymethod----cosmeticspecificationandcheckingmethod----plantlayout----operatortrainingandshiftarrangement

ProductionLineSetting:50Quality:-----controlplanandflowchart,-----environmentaudit-----processaudit-----GR&R-----goldensample-----trialrunpremises-----processqualificationrequirementOtherProblem:-----finance-----logistics-----securityQuality:51

ExecutionphaseAssoonascustomergivesgosignal,theNPIispromotedinto“executivephase”andachecklistneedtobemade.NO.CheckItemaAVLandBOMbProductioncPackingDesignandInstructiondQualitydocumentseCustomerSpecificationandGoldenSamplefCapitalExpenditureExecutionphaseNO.CheckItem52

Productiondocuments:a>

ProcessFlow-chartb>SOP(orMI/WI)c>TestInstructiond>FinalInspectionInstructione>PackingDesignandInstruction.a>PFMEAb>ControlPlanc>GR&Rd>CapabilityStudye>PQPPlan.

Productiondocuments:

AVL(AML)andBOM:Productiondocuments:a>Proc53

CustomerSpecification&GoldenSample(ifapplicable):a>

Makesurethelatestqualityandproductspecificationwasgot,andrenewaloftestsoftware.b>Qualityengineershouldtransferthespecificationintointernalformat.c>Testingengineershouldhaveasoftwareupgradelist.d>FinalInspectionInstruction.e>Differentdocumentversionmaybeappliedtodifferentproductversion.

CapEx:

-----CheckthatapprovedCapExisavailable.

CustomerSpecification&Gold54

Trial-runPhase-----CustomerreleasedformalPO#andconfirmedprice,westarttrialrun.Theoutputistrialrunreportfromengineerteam.Theresultistrialrunsampleapprovedbycustomerandgiveramp-upsignal.