新产品导入程序管理.ppt

1、NPI PROGRAM MANAGEMENT 新产品导入程序管理,INDEX,Introduction for NPI,The Focus for NPI,What is customers most concern during NPI process?,NPI Process,NPI is becoming more and more important in most manufacturing companies. It is the first step to win customer confidence on both production capability and busi

2、ness management.,Introduction,Full Name of NPI: New Product Introduction,CONTENT,NPI locates between design and mass production and it is a verifying process to product design and production.,How to get profit from the NPI business;,The Focus for NPI,Standing as manufacturing service provider, we ne

3、ed focus on followings:,How to manage the NPI business;,How to come out a proper NPI report to customer to get customer approval;,How to transfer the NPI to factory to implement mass production smoothly;,For the supplier: a Quality b Capacity,What is customers most concern during NPI process?,For th

4、e product: a Enough training to operators and engineers b Product requirement are clear and implemented solidly c Process setup adequately d Process evaluation is ready,-The practice and lesson learnt in NPI phase are most important as customer is prefer to solve all problems which are related to de

5、sign and system fault at this phase, not mass production phase.,Pre-study Phase,NPI Process,Planning Phase,Execution Phase,Trial-run Phase,Ramp-up Phase,Transfer Phase,Pre-study Phase,-Sales manager will call related people to review the sales offer, forecast, project budget and agreement.At the sam

6、e time,product engineers need to ask for the informations such as product specifics and production requirement from PM or customer to know the prouct in advance.,Planning Phase,-This phase is very important to whole program. PM should have a detailed list to review one by one to ensure all informati

7、on are ready and all plan have responsible people and deadline.,a Project milestone(Schedule) b Project organization(Team) -Process Engineer/SMT Engineer/Diagnostic Engineer/Quality Engineer/Program Manager / Sales/Buyer/Planner/PDM(product document manager)/Finance etc. c Investment plan -PM or hig

8、her hierarchy to define the investment. The investment includes equipment cost, tooling & jig & fixture cost, training cost and renovation cost. Most cost has been put into quotation and now we need control it by items.,d Facility plan. PM should call production manager, WH manager, facility manager

9、 to define the location: -which SMT line can be adequate use? -where to allocate the production line? -where to store the finished goods ?,e Material management plan. -We need Material Manager to discuss the purchasing plan and delivery plan if consigned material there is. -This plan is very serious

10、 to make sure there is no material shortage. -Shortage is very easy occurred on three cases: single source DOS (days of supply) too long bad BOM usage For this case, we can use safe stock to control.,f Quality plan. -Quality dept. should provide quality control plan, sub-supplier management plan, FM

11、EA, environment report (if applicable).,g Manufacturing plan: -Production manager should report the manpower allocation and make the training plan to operators. -IE should finished the layout plan and standard time calculation, based on the volume, shift arrangement, operator quantity, line layout,

12、tooling & equipment balance, technical people support. -Test engineer should also feedback the running status to PM. h Risk management plan: -Not all potential problems would occur, but if occur, some plan and work may going to “death”.,i ECR/ECO plan: -PDM and product engineer should control this p

13、lan. PM have to concern about once the engineering change would cause cost change. So, to define an ECR/ECO handling procedure and cost control process are necessary.,j CPM analysis and back-up solution consideration: -CPM:Critical Path Method -When all plans were ready, PM should have a review to a

14、ll these activities as a by-stage come-out. We title the review meeting as “planning review” or “start-up review”. The purpose is to make sure all activities are under control and running as what we expected.,-Following here are some Items which are critical and need high attention in the review mee

15、ting:,General Information: -customer milestone -capacity -volume -dedicated project personnel Supply Chain Management: -the focus is on procurement management and component coding (or BOM coding). Before the meeting, Material people should review the BOM and check out which ones are critical compone

16、nts. The critical component mainly means supplier-controlled market and/or high-value unique component.,Production Line Setting: -SMT package (Gerber, X-Y, PCN drawing) -assembly process -packing requirement (domestic and export) -traceability -testing software and hardware -tooling preparation -del

17、ivery method -cosmetic specification and checking method -plant layout -operator training and shift arrangement,Quality: -control plan and flow chart, -environment audit -process audit -GR&R -golden sample -trial run premises -process qualification requirement Other Problem: -finance -logistics -sec

18、urity,Execution phase,As soon as customer gives go signal, the NPI is promoted into “executive phase” and a checklist need to be made.,Production documents:,a Process Flow-chart b SOP (or MI/WI) c Test Instruction d Final Inspection Instruction e Packing Design and Instruction.,a PFMEA b Control Pla

19、n c GR&R d Capability Study e PQP Plan.,Production documents:,AVL(AML) and BOM:,Customer Specification & Golden Sample (if applicable):,a Make sure the latest quality and product specification was got, and renewal of test software. b Quality engineer should transfer the specification into internal f

20、ormat. c Testing engineer should have a software upgrade list. d Final Inspection Instruction. e Different document version may be applied to different product version.,CapEx: -Check that approved CapEx is available.,Trial-run Phase,-Customer released formal PO# and confirmed price, we start trial r

21、un. The output is trial run report from engineer team. The result is trial run sample approved by customer and give ramp-up signal. -The trial run report should cover the processes from SMT to packing and shipment. We should raise action plan for all critical problems and potentials necessarily. Aft

22、er trial run, sample would be sent to customer based on request.,-After trial run, sample would be sent to customer based on request. -In most cases, the whole NPI can be lengthened or shortened due to many factors, and it is also naturally have direct correlation to customer demand.,functionality,c

23、omplexity,requirement,predicted volume,There are 4 basic factors:,Ramp-up Phase,-The trial run sample was approved by customer and “go-signal” was released, it means we can move to “ramp-up phase” successfully. -This is the final phase for NPI. We must check what is lost or need further improvement

24、for factory production. -In fact, customer would give updated forecast and MRP plan now.Planner can make production schedule based on that.,Transfer Phase,-When customer approved the Ramp-up plan, NPI PM has to call a meeting with factory steering to transfer the project and report to customer about the transfer. -prepare a completed NPI report to factory members to make the transfer successful. - KPI (Key Performance Indicators) KPI