archetypes case study part 6, 7 & 8 june 24, 2013
DESCRIPTION
Product development case studyTRANSCRIPT
part 5 of 7 part Case Study
1 Product development
Luxury brand Case Study
2
Notes
3
November 2012
Max Ruckman, Black & Decker HHI
Project Team
Luxury Brand
Business
Development
Case Study Part 6-8
www.maxruckman.com
4
Phase vi
produ
ction
all agency listings and quality plans are complete and on the line
Bulk build & test
Definition
first full production lot
after the final pilot and
conducted using
production tooling, by
trained persons
approved capital equipment
Bulk build & test
Inputs
clean pilot lot i.e. no product design, tooling or process changes
successful pilot lot test results
statistically significant reliability assurance test results from the laboratory and field
ramp up goals
production plan
launch plan agreed upon by team and marketing
confirmed product cost
productivity / waste & variances
Bulk build & test
Actions
build product
safety / process & variances
inventory
measure to all promised deliverables
quality first time pass & finished stock audit
service level
bulk production review: program manager
to hold monthly post production review,
includes resident engineer
Bulk build & test
Deliverables
salable product for
release to distribution
action plan to address misses
second pilot of “Product X” was run on “date” at the
manufacturing facility consisting of 120 units
Pilot lot build
summary
this product is very similar in construction to the
existing “product y” products being built at the
manufacturing facility, and therefore the majority of the processes already in place were carried
forward when this product was built
Pilot lot build
summary
there are three exceptions in the component assembly area
Pilot lot build
summary
the operators experience minimal disruption or problems when assembling these components
Pilot lot build
summary
mechanism
design was changed to eliminate “problem A” that occurs in “product X” when under extreme environmental conditions
a plastic spring retainer was replaced with a powdered metal plate and six steel pins.
no action required
Pilot lot build
summary
this must be closely monitored by all team members
Pilot lot build
summary
final recommendation: to insure
the product meets the highest
quality standards a
comprehensive audit plan must
be followed, with special attention to the sub-assemblies
add other issues as needed
Pilot lot build
summary
cartons
all artwork completed
all revisions and changes were made to carton art work to new
information per marketing request
any other changes required to packaging
Pilot lot test
Packaging example
“product x” products have been through several different builds,
each time with major improvements to the durability of the design
Pilot lot test
Product testing summary
the following schedule summarizes the builds
august 2011 prototype build 20 units
october 2011 esl 1 46 units
january 2012 esl 2 145 units
march 2012 pilot lot 1 80 units
april 2012 pilot lot 2 120 units
Pilot lot test
Product testing summary
tested 54 units including all builds
Pilot lot test
field testing
typical uses: door installation
typical users: home builders, DIYer’s
logged over 5,250 days in the field
Product testing summary
application based reliability testing
tested approximately 120 units on destructive cycling test
applications: list uses tests performed
Pilot lot test
in-house testing
remaining tests: in the process of completing all rig testing for a complete
analysis of the pilot lot units continuing application testing until failure
Product testing summary
agency certification
all testing has been
completed and certification
was received if applicable
Pilot lot test
Product testing summary
Phase vii
distri
bution
audit of product to confirm its acceptable for release to distribution
Sqa confirm
Definition
audit results
test results
engineering test results
Sqa confirm
Inputs
supply standard
manufacturing procedures as
dictated by audit results
Sqa confirm
Actions
release the product to distribution on concluding a “good” result
Sqa confirm
Deliverables
replacement parts must be available in the service
warehouse before product introduction so they can be
used by the service and reconditioning centers
Service spares
Definition
manufactured cost of spare parts
Service spares
Inputs
complete engineering BMO & related part drawings
product sales forecast
forecast of replacement parts inventory using in-house testing results
structure of all part masters in supplier database
receive, inspect and
place replacement
parts into inventory
Service spares
Actions
structure service part masters
develop service BOM
develop list of recommended initial parts order quantities
determine initial parts order quantities
place orders for replacement parts
ready-to-order
replacement parts
inventory in service
base warehouse
Service spares
Deliverables
Phase viii
Program
Target
scoring
access performance of existing similar product to carry-over good features and avoid
recurrence of “old” problems
Post audit
Definition
assist in provision of product feedback
(after-the-sale)
request from product team for
feedback on current product
Post audit
Inputs
request from
project team to add product to
early warning
discuss performance of existing similar product with project team (by service repair and/or reconditioning technicians to identify strengths and weaknesses of current similar products)
Post audit
Actions
provide feedback to project team on after-the-sale performance of the product
add product to early warning program
product feedback information on similar, current product
Post audit
Deliverables
after-the-sale feedback on new products
November 2012
Max Ruckman, Black & Decker HHI
Project Team
Luxury Brand
Business
Development
Case Study Part 6-8
www.maxruckman.com
37