dtengineering 1 of 31 the product development process activity

1 of 31dtengineering

The Product Development Process

Activity


Product Development Process Overview

The product development process is a procedure by which an idea may be turned into a real product which can be manufactured and eventually sold to a customer.

The product development process is broken down into the following six steps called phases:

Phase 1: Proposal

Phase 2: Investigation

Phase 3: Lab Prototype

Phase 4: Production Prototype

Phase 5: Pilot Run

Phase 6: Manufacturing Release


Product Development Process Overview (continued)

The people involved in these phases come from different departments in a company. The departments are as follows:

Marketing

Finance

Engineering

Quality

Manufacturing


Case Study

We will create a company that manufactures and sells portable fuel containers. Marketing has determined that we need to offer a specialized fuel container that targets lawn tractors, off-road motorcycles and personal watercraft. After talking with potential customers, marketing has decided that the fuel container must have the following features:

Five(5)-gallon capacity

Automatically opening and closing fuel cap

Automatic venting

Automatic fuel stop when tank is full

Will not leak when tipped over

Child-proof fuel cap

Meets current EPA standards

The following activities will lead you through some of the tasks required to turn this marketing request into a real product.


Phase 1: Proposal Phase – Explanation

Program Definition

Objective:

To create/propose a new product idea

Participants:

Marketing, Finance, Engineering, Quality, Manufacturing

Sample Activities:

Definition of program/product requirements

Checkpoint meeting

Sample Deliverables:

Product Proposal


Phase 1: Proposal Phase – Key Terms

ProposalA proposal is a plan prepared by the product development team that outlines the new product idea, customers, and estimates of the cost and time required to complete a project. The engineering, marketing, manufacturing, quality and finance departments are involved in preparing the proposal.

Product RequirementsProduct requirements are the features and cost targets that the product must meet. The product requirements are obtained by marketing research and are defined in the Market Requirements Document. It is used by everyone involved in the development process to direct the product design.

Market Requirements Document (MRD)The market requirements document (MRD) outlines the product requirements. The marketing department prepares the MRD based on the needs of the end user. The MRD is used as a reference for all members of the product development team to ensure that the most important requirements of the product are met. The MRD will direct how the engineers develop the product.


Phase 1: Proposal Phase – Key Terms (continued)

Concurrent Product DevelopmentConcurrent product development is the process whereby departments are involved in the product development process from beginning to end. Concurrent product development saves time and money. It requires regular review meetings in which the marketing, finance, engineering, quality, and manufacturing departments are kept up to date with one another’s progress.

Front-End ResearchFront-end research is research done by the marketing group to determine the type of product customers might buy, what features it must have, and how much customers would be willing to pay for it. The front-end research results will be used to help create the MRD.

Review MeetingA meeting involving all of the departments responsible for the development of the product is called a review meeting. The group reviews the work completed and discusses any issues which may affect the development of the product.


Phase 1: Proposal Phase – Activity

Marketing Activity

Summary:

One of the responsibilities of the marketing department during the proposal phase is to decide how many units will be sold and what the target price will be. This information is used to determine how profitable the product will be and which manufacturing methods will be used.

Activity:

Using the following questions, determine how many units will be sold and, if possible, the target retail price:

1. Who is the target customer?

2. How much are they willing to pay for this product?

3. Who are the competitors and what do similar products sell for?

4. How many similar units are sold annually?

5. How many products will we sell?


Phase 2: Investigation Phase – Explanation

Design Concept Cycle

Objective:To investigate the engineering specifications of the product and verify that they can be achieved. Participants:Marketing, Finance, Engineering, Quality, Manufacturing

Sample Activities:System architectureSimulationSubsystem modeling and analysisCross-functional design reviewCheckpoint meeting


Phase 2: Investigation Phase – Explanation (continued)


Documented feedback from the customer, manufacturing, safety and regulatory

Breadboard designs

Profitability study

Updated schedule and plan

Team assignments (renewed/revised) for the next phase


Phase 2: Investigation Phase – Key Terms

Feasibility StudyResearch done by the engineering department to determine if the product requirements can be met is a feasibility study. If the engineers determine that the requirements cannot be met, or if the cost of meeting them is excessive, the engineering and marketing departments must work together to adjust the product requirements. The finance department may also be involved and decide at any time that the project is not worth pursuing.

Back-of-the-Napkin SketchA rough sketch of a design concept is sometimes called a back-of-the-napkin sketch. It is usually prepared by an engineer to communicate an idea. A back-of-the-napkin sketch is not necessarily drawn on a napkin, but the name suggests the informal and preliminary nature of the sketch.

Bread Board DesignA bread board design is a preliminary functional prototype created by the engineering department to test a concept's viability. A bread board is not necessarily intended to meet all of the product requirements or to look like the end product.


Phase 2: Investigation Phase – Key Terms (continued)

System ArchitectureA conceptual overview of what elements are needed in a system and how they will fit together is called the system architecture. It is performed by the engineering department and will be reviewed by the marketing and manufacturing departments.

Ergonomics StudyAn ergonomics study is a design study involving the interaction of humans with a product. The engineers who design keyboards, door handles, telephones and other products need to consider the human body and behaviors to ensure that the product can be used easily, safely, and comfortably.

Profitability StudyA profitability study examines the costs and benefits of developing a product. The finance department will consult with the marketing, engineering, and manufacturing departments to determine the profitability of a product. As the development process proceeds and more information becomes available, the finance department will reassess the profitability of the product.


Phase 2: Investigation Phase – Activity

Finance Activity

Summary:

The most important consideration for a company developing a new product is profitability. The finance department must weigh the costs and benefits of proceeding with the product development process. It will try to determine whether or not this product will be a good investment.

Activity:

Use the following questions to try to determine whether or not the product will be a good investment for the company.

1. What are some of the costs associated with developing the product?

2. What are some of the costs associated with manufacturing the product?

3. What are some of the costs associated with selling the product?

4. Based on the marketing information determined in the proposal phase, what is the gross annual revenue?


Phase 3: Lab Phase, Part 1 – Explanation

Engineering Prototype Cycle

Objective:

To develop and document a product that meets customer, engineering, manufacturing, quality, and business specifications.

Participants:


Sample Activities:

Functional prototypes

Design verification testing

Safety regulatory compliance testing

Cross-functional design review

Checkpoint meeting


Phase 3: Lab Phase Part 1 – Explanation (continued)


Part and assembly databases

Bill of materials

Marketing literature

Product manuals

Schedule update


Phase 3: Lab Phase, Part 2 – Explanation

Lab Prototype Builds

Description:

Prototype builds are designated as LP1, LP2, LP3, etc. with the number of builds (and quantity of parts/units) determined during the proposal and investigation stages based on the complexity of the program. The lab prototype builds are executed during the lab phase of the process.

Objectives:

To verify the design assumptions (including any unit testing required).

To verify proper operation of all hardware, software, and mechanical systems.

To examine the product for manufacturability and assembly optimization.

To examine the product for cost optimization and common part utilization.

To provide units based on customer requirements.

To confirm manufacturing target costs have been met.


Phase 3: Lab Phase; Key Terms

Lab Prototype

A preliminary build of a product to make sure that it meets the product requirements is a lab prototype. The engineering department usually oversees the design, fabrication and testing of a lab prototype.

Bill of Materials (BOM)

A list created by the engineering department which specifies the parts and hardware needed to assemble a product is a bill of materials. The manufacturing department will use the BOM when they are looking for suppliers.

Design for Manufacturability (DFM)

Design for manufacturability is a method used by the engineers to ensure that the product can be manufactured in a cost-effective way. The manufacturing department can review the design and provide feedback on its manufacturability.


Phase 3: Lab Phase – Activity

Engineering Activity

Summary:

Engineers must create a prototype product which meets customer specifications at the given price point. The first thing they need to do is to brainstorm possible solutions.

Activity:

Engage in a brainstorming session and try to come up with at least five(5) possible designs for a fuel container filler cap. Vote to see which design solution the class thinks might be the best. The design must meet the following specifications:

1. The nozzle opens and closes without reconfiguring.

2. It will not leak when tipped over.

3. It must have a filler cap which is child-proof.


Phase 4: Production Prototype Phase, Part 1 – Explanation

Manufacturing Prototype Cycle

Objective:

To design, test, and verify all in-house manufacturing and external supplier processes required to build the product at production volumes.

Participants:


Sample Activities:

Fabrication and assembly processes checked

Definition and implementation of assembly lines and processes

Checkpoint meeting


Phase 4: Production Prototype Phase, Part 1 – Explanation (cont’d)

Manufacturing Prototype Cycle:


Manufacturing plan

Final production costs

First article inspection reports

Completed tooling

Completed product manuals


Phase 4: Production Prototype, Part 2 – Explanation

Production Prototype Build

Description:

Prototype builds are designated as PP1, PP2, PP3, etc. with the number of builds (and quantity of parts/units) determined during the proposal and investigation stages based on the complexity of the program. The Production Prototype build is performed using all established internal and external sources.

Sample Objectives:

To test and verify all manufacturing tooling.

To test and verify all processes that will be required to build production volumes.

To perform qualification testing on finished product.


Phase 4: Production Prototype Phase – Key Terms

First Article Inspection

A first article inspection is a check performed by the quality department to ensure that the first production parts meet the specifications of the design.

Production Volume

The number of products that will typically be built when the product is in production is called the production volume. The marketing, manufacturing, and finance departments will determine the production volume.

Tooling

Tooling is special tools that are needed to manufacture a product. Certain manufacturing processes require special tooling, such as mold-injected plastics, aluminum extrusions, metal die-casts and composites. Additionally, special tooling may be required for manufacturing assembly processes.


Phase 4: Production Prototype Phase – Key Terms (continued)

Production Prototype

A production prototype is a manufacturing build of the product that tests the manufacturing systems.

Supplier

A supplier is an outside company which provides parts or services in the production of a product. The manufacturing department oversees the selection of suppliers based on their ability to provide parts or services that meet the design specifications at a competitive price.

In-House Manufacturing

A manufacturing process which uses a company's own resources is called in-house manufacturing. Many companies today have moved away from in-house manufacturing in favor of using external suppliers.


Phase 4: Production Prototype Phase – Activity

Manufacturing Activity

Summary:

The production prototype phase helps the manufacturing department build and test their manufacturing system. They will also try to reduce the cost and time to manufacture the product during this phase.

Activity:

Brainstorm five(5) ways to reduce assembly time. Use the following information to discover where to begin:

1. Using a stopwatch, record the time required to assemble the product.

2. Marketing predicts that you will have to build 10,000 units per month. Given that one person works 40 hours per week, decide how many people you will need to hire to build this product at the required volumes.


Phase 5: Pilot Phase – Explanation

Pre-Production Cycle

Objective:

To perform final manufacturing system qualification testing and test/fill distribution pipeline.

Participants:


Sample Activities:

Volume product build

Distribution testing and verification

Supply chain testing and verification

Checkpoint meeting


Phase 5: Pilot Phase – Explanation (continued)


Distribution test report

Supply chain test report

Completed checkpoint signoff sheet


Phase 5: Pilot Phase – Key Terms

Distribution Pipeline

A distribution pipeline is the chain of organizations or companies responsible for the distribution of the product to the end user. This includes shipping/receiving, trucking companies, distributors and retailers.

Supply Chain

The group of organizations or companies responsible for supplying parts or products to the manufacturer is called a supply chain.

Pre-Production Build

A pre-production build is a final test-run performed to verify manufacturing consistency, supply chains, and distribution systems. It is the culmination of the efforts that lead up to a full Manufacturing Release of the product.


Phase 5: Pilot Phase – Activity

Quality Activity

Summary:

The quality department is responsible for making sure that the product is made correctly. They measure sample parts for dimensional accuracy and perform tests on completed assemblies. If any problems are discovered the quality department will determine how to correct it.

Activity:

Test the functionality of the product to decide if it will work properly for the customer.

1. Does the valve open and close reliably?

2. Fill the jug to the top with water and install the cap.

3. Turn the jug upside down and check for leaks.

4. Using a stopwatch, record the time the jug takes to empty. Does it take less than one minute?


Phase 6: Manufacturing Release – Explanation

Production

Objective:To release the product to manufacturing for volume production.

Participants:Marketing, Finance , Engineering, Quality, Manufacturing

Sample Activities:Transfer all product databases to production control Manufacturing Release meeting

Sample Deliverables:SchematicsPart and assembly databasesBill of materialsProduct manual databasesRelease meeting signoff sheet


Phase 6: Manufacturing Release – Key Terms

Marketing Literature

Marketing literature is material which announces or promotes a product. It includes brochures, flyers and advertisements.

Company Product List

A company product list is a list of products that a company sells and the prices.

Product Support

Product Support is a method a company uses to answer the customer’s questions and to help them resolve problems that they may have with the product. It can include phone support, web site support, and utilizing retail outlets.


Phase 6: Manufacturing Release – Activity

Administrative ActivitySummary:The product development process has been completed and all related documents are ready to be handed over to the manufacturing department. The company’s owner or general manager will meet with department heads and project managers to confirm that everyone involved is ready to begin production.The company’s owner or general manager may hold a site-wide meeting to build excitement and cooperation among employees. Presentations may be made describing the new product, the company’s hopes for it in the marketplace, and the importance of the employees in making the product a success.

Some activities beyond the product development process:1. Product added to company product list2. Distribution of marketing literature3. Product support comes on line

This work was funded through the California Community College Chancellor’s Office grant #07-171-002 (SB1133) and the Sierra College CTE Community Collaborative (Sierra STEM) project.

dtengineering 1 of 31 the product development process activity

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