新产品导入程序管理

NPIPROGRAMMANAGEMENT新产品导入程序管理INDEXIntroductionforNPITheFocusforNPIWhatiscustomer’smostconcernduringNPIprocess?NPIProcessNPIisbecomingmoreandmoreimportantinmostmanufacturingcompanies.Itisthefirststeptowincustomerconfidenceonbothproductioncapabilityandbusinessmanagement.IntroductionFullNameofNPI:NewProductIntroductionCONTENTNPIlocatesbetweendesignandmassproductionanditisaverifyingprocesstoproductdesignandproduction.HowtogetprofitfromtheNPIbusiness;TheFocusforNPIStandingasmanufacturingserviceprovider,weneedfocusonfollowings:HowtomanagetheNPIbusiness;HowtocomeoutaproperNPIreporttocustomertogetcustomerapproval;HowtotransfertheNPItofactorytoimplementmassproductionsmoothly;Forthesupplier:aQualitybCapacityWhatiscustomer’smostconcernduringNPIprocess?Fortheproduct:aEnoughtrainingtooperatorsandengineersbProductrequirementareclearandimplementedsolidlycProcesssetupadequatelydProcessevaluationisready---------ThepracticeandlessonlearntinNPIphasearemostimportantascustomerisprefertosolveallproblemswhicharerelatedtodesignandsystemfaultatthisphase,notmassproductionphase.Pre-studyPhaseNPIProcessPlanningPhaseExecutionPhaseTrial-runPhaseRamp-upPhaseTransferPhasePre-studyPhase----------Salesmanagerwillcallrelatedpeopletoreviewthesalesoffer,forecast,projectbudgetandagreement.Atthesametime,productengineersneedtoaskfortheinformationssuchasproductspecificsandproductionrequirementfromPMorcustomertoknowtheprouctinadvance.PlanningPhase-----------Thisphaseisveryimportanttowholeprogram.PMshouldhaveadetailedlisttoreviewonebyonetoensureallinformationarereadyandallplanhaveresponsiblepeopleanddeadline.ITEMRELATEDPLANSaProjectmilestonebProjectorganizationcInvestmentplandFacilityplaneMaterialmanagementplanfQualityplangManufacturingplanhRiskmanagementplaniECR/ECOplanjCPManalysisandback-upsolutionconsiderationaProjectmilestone(Schedule)bProjectorganization(Team)-----ProcessEngineer/SMTEngineer/DiagnosticEngineer/QualityEngineer/ProgramManager/Sales/Buyer/Planner/PDM(productdocumentmanager)/Financeetc.cInvestmentplan-----PMorhigherhierarchytodefinetheinvestment.Theinvestmentincludesequipmentcost,tooling&jig&fixturecost,trainingcostandrenovationcost.Mostcosthasbeenputintoquotationandnowweneedcontrolitbyitems.dFacilityplan.PMshouldcallproductionmanager,WHmanager,facilitymanagertodefinethelocation:-----whichSMTlinecanbeadequateuse?-----wheretoallocatetheproductionline?-----wheretostorethefinishedgoods?eMaterialmanagementplan.-----WeneedMaterialManagertodiscussthepurchasingplananddeliveryplanifconsignedmaterialthereis.-----Thisplanisveryserioustomakesurethereisnomaterialshortage.-----Shortageisveryeasyoccurredonthreecases:singlesourceDOS(daysofsupply)toolongbadBOMusageForthiscase,wecanusesafestocktocontrol.fQualityplan.-----Qualitydept.shouldprovidequalitycontrolplan,sub-suppliermanagementplan,FMEA,environmentreport(ifapplicable).gManufacturingplan:-----Productionmanagershouldreportthemanpowerallocationandmakethetrainingplantooperators.-----IEshouldfinishedthelayoutplanandstandardtimecalculation,basedonthevolume,shiftarrangement,operatorquantity,linelayout,tooling&equipmentbalance,technicalpeoplesupport.-----TestengineershouldalsofeedbacktherunningstatustoPM.hRiskmanagementplan:-----Notallpotentialproblemswouldoccur,butifoccur,someplanandworkmaygoingto“death”.iECR/ECOplan:-----PDMandproductengineershouldcontrolthisplan.PMhavetoconcernaboutoncetheengineeringchangewouldcausecostchange.So,todefineanECR/ECOhandlingprocedureandcostcontrolprocessarenecessary.jCPManalysisandback-upsolutionconsideration:-----CPM:CriticalPathMethod-----Whenallplanswereready,PMshouldhaveareviewtoalltheseactivitiesasaby-stagecome-out.Wetitlethereviewmeetingas“planningreview”or“start-upreview”.Thepurposeistomakesureallactivitiesareundercontrolandrunningaswhatweexpected.-----FollowingherearesomeItemswhicharecriticalandneedhighattentioninthereviewmeeting:NO.CriticalItemsaGeneralInformationbSupplychainmanagementcProductionlinesettingdQualityeOtherproblemGeneralInformation:-----customermilestone-----capacity-----volume-----dedicatedprojectpersonnelSupplyChainManagement:-----thefocusisonprocurementmanagementandcomponentcoding(orBOMcoding).Beforethemeeting,MaterialpeopleshouldreviewtheBOMandcheckoutwhichonesarecriticalcomponents.Thecriticalcomponentmainlymeanssupplier-controlledmarketand/orhigh-valueuniquecomponent.ProductionLineSetting:----SMTpackage(Gerber,X-Y,PCNdrawing)----assemblyprocess----packingrequirement(domesticandexport)----traceability----testingsoftwareandhardware----toolingpreparation----deliverymethod----cosmeticspecificationandcheckingmethod----plantlayout----operatortrainingandshiftarrangementQuality:-----controlplanandflowchart,-----environmentaudit-----processaudit-----GR&R-----goldensample-----trialrunpremises-----processqualificationrequirementOtherProblem:-----finance-----logistics-----securityExecutionphaseAssoonascustomergivesgosignal,theNPIispromotedinto“executivephase”andachecklistneedtobemade.NO.CheckItemaAVL