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1、NPI PROGRAM MANAGEMENT 新产品导入程序管理新产品导入程序管理INDEXuIntroduction for NPIuThe Focus for NPIuWhat is customers most concern during NPI process?uNPI ProcessNPI is becoming more and more important in most manufacturing companies.It is the first step to win customer confidence on both production capability an
2、d business management.uIntroductionFull Name of NPI:New Product IntroductionCONTENTNPI 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;uThe Focus for NPIStanding as manufacturing service provider,we nee
3、d 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 uWhat is customers most concern during NPI process?For the prod
4、uct: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 design an
5、d system fault at this phase,not mass production phase.Pre-study PhaseuNPI 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 same time,produ
6、ct 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 information are ready a
7、nd all plan have responsible people and deadline.ITEMRELATED PLANSaProject milestonebProject organizationcInvestment plandFacility planeMaterial management planfQuality plangManufacturing planhRisk management planiECR/ECO planjCPM analysis and back-up solution considerationa Project milestone(Schedu
8、le)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 higher hierarchy to define the investment.The investment includes equipment cost,tooling&jig&fixtu
9、re 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 to define the location:-which SMT line can be adequate use?-where to allocate the production line?-where t
10、o 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 to make sure there is no material shortage.-Shortage is very easy occurred on three cases:single sourceDOS(days o
11、f 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,FMEA,environment report(if applicable).g Manufacturing plan:-Production manager should report the manpower allocation and make
12、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,tooling&equipment balance,technical people support.-Test engineer should also feedback the running status to PM.h Risk management plan:
13、-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 plan.PM have to concern about once the engineering change would cause cost change.So,to define an ECR/ECO handling procedure and cost control proce
14、ss 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 all 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
15、are under control and running as what we expected.-Following here are some Items which are critical and need high attention in the review meeting:NO.Critical ItemsaGeneral InformationbSupply chain managementcProduction line settingdQualityeOther problemlGeneral Information:-customer milestone -capac
16、ity -volume -dedicated project personnellSupply 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 components.The critical component mainly means supplier-controll
17、ed market and/or high-value unique component.lProduction Line Setting:-SMT package(Gerber,X-Y,PCN drawing)-assembly process -packing requirement(domestic and export)-traceability -testing software and hardware -tooling preparation -delivery method -cosmetic specification and checking method -plant l
18、ayout -operator training and shift arrangement lQuality:-control plan and flow chart,-environment audit -process audit -GR&R -golden sample -trial run premises -process qualification requirementlOther Problem:-finance -logistics -security Execution phase As soon as customer gives go signal,the NPI i
19、s promoted into“executive phase”and a checklist need to be made.NO.Check ItemaAVL and BOM bProduction cPacking Design and InstructiondQuality documentseCustomer Specification and Golden Sample fCapital Expenditure l Production documents:a Process Flow-chartb SOP(or MI/WI)c Test Instructiond Final In
20、spection Instructione Packing Design and Instruction.a PFMEAb Control Planc GR&Rd Capability Studye PQP Plan.l Production documents:l AVL(AML)and BOM:l Customer Specification&Golden Sample(if applicable):a Make sure the latest quality and product specification was got,and renewal of test software.b
21、Quality engineer should transfer the specification into internal format.c Testing engineer should have a software upgrade list.d Final Inspection Instruction.e Different document version may be applied to different product version.l CapEx:-Check that approved CapEx is available.Trial-run Phase-Custo
22、mer released formal PO#and confirmed price,we start trial run.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 fo
23、r all critical problems and potentials necessarily.After 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
24、 correlation to customer demand.functionalitycomplexity 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
25、 is lost or need further improvement 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 proj
26、ect and report to customer about the transfer.-prepare a completed NPI report to factory members to make the transfer successful.-KPI(Key Performance Indicators)KPIs are measures to a NPI project:PM has to review the actual vs target.PM need review the actual vs target.-Project time schedule-Project
27、 budget(from CapEx and Process performance,e.g.Yield,scrap rate,etc)-Line capacity Documents for KPIs:CapEx and Investment plan-Project Management Document Quotation report Project organization and meeting,necessary presentationBOM&ECO Product log,including all product change Drawing&Specification-P
28、roduct Information Quotation report Layout and facility requestStandard time calculation Ramp-up plan Control plan,flow chart and PFMEA-PQP Documents:Quotation report Capability&GR&R report Work instructions SMT documents-Process Requirement:Assembly documents Testing document Traceability requirement Packing and shipping requirement Others THE END