NPD-新产品开发控制课件.ppt

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1、A member of ASE Group New Product DevelopmentNPD(新產品開發流程)陳堅慈(Fred Chen),June 14-20022為何需要新產品開發與流程?新產品開發是什麼?一個團體根據需要,訂定計劃,組織人員,開發設計與驗證樣品,並使之能大量複製與販售之過程稱之新產品開發流程.為何需要新產品開發?一個以服務產生營利之團體,為使之利潤來源能持續不斷,必需在 原有產品利潤降低或開拓新事業領域時,進行新產品開發以維持適當利潤使團體存活.新產品開發風險 大量複製代表大量材料與金錢投入,若產品有任何重大瑕疵,將會造成產品退貨,輕者損失商譽賠錢解決,嚴重可能使公司

2、經營發生困難降低風險提升利潤 經由適當有效流程控制,複製經驗,確保產品開發品質控管機制,以提升量產之品質,減低公司營運風險;經由經驗分享,減少犯錯機會,降低開發時間,使產品快速上市,以取得最佳利潤.3PDCA LoopPlan:To have a plan,(What it is,How and When to do,How to check )Do:Follow plan to do Check:Follow plan to do checking Action:To assess the effectiveness of result with plan PDCA(Plan/Do/Chec

3、k/Action)PlanDoCheckAction(Quality/品質,Cost/成本,Delivery/交期 )4Life Cycle of Product市場Marketing終止End of Life企劃Planning開發設計Design試作/Sample評價/Evaluation試產Pilot Run量產Mass Production5Resource of Development Product Design CapabilityPOWERPublicationProduct EngineeringThermalDesignMechanicalIDBIOSS/WF/WElect

4、ronicHardwareReliability TestingCompatibility TestingTestingProgramTesting FixturePCBLayoutSimulation Pre_LoadManufacturingEMC/Safety6Concept DesignDVTMVTEVT Mass ProductionStartPlanning EVT:Engineer Verification Test ,DVT:Design Verification Test ,MVT:Manufacturing Verification TestProduct Developm

5、ent Control Flow Pass Pass Pass Fail Fail Fail Gating Gating Gating 開發設計DevelopmentDesign 樣品製作Sample Build樣品評價VerificationValidation試產Pilot Run NPD NPINPD:New Product Development NPI:New Product Introduction 7NPD/NPI NPI OperationMass ProductionODM ProjectOEM Project NPI OperationNPDOperation NPI:Ne

6、w Product Introduction Focus on a product be phased in manufacturing related activities.NPD:New Product Development Except the NPI activities,It also included product design and design verification and validation related activities.Pass Fail Gating NPI Operation8 NPI (New Product Introduction)NPI :A

7、 process to make a product be produced,delivered to customer or market.Product document transferringPilot RunMass ProductionYield rate improvementTechnical/Quality requirementFailure analysis,reliability test Early Manufacturing Involvement DFM/DFT review&feedbackManufacturing Readiness Review Plan,

8、Tooling,spec.,documentSet up project teamProject team listdepends on cooperation modelE.C.M.Prototyping 1,2 Sample making E.C.M.:Engineering Change Management:ECR/ECN 9CustomerrequestPrepare InitiatorCheck Section manager of initiator CirculateRelated DepartmentApprove QRB ChiefReleaseDocument cente

9、r AgreeReject(if someone disagree)Get approval from customerrequest for change (material,process)PDM work flowInitiator USI internal related dept.ImplementECR/ECN in PDM 101.2.3.21+ChaptersMM*/Site5 BooksQualityManualFunction Procedures&Product InstructionsIndividual Product spec.,Drawing,etc.(大QM)(

10、500 q)Current StructuresCurrent StructuresT.P.D.OFProductMaterialMethod(Process)MachineBOMDrawingSpec.Instruction過期或不適用資料 T.P.D.RelatedWithin Dept.Cross Dept.Cross FunctionNew StructuresNew StructuresNew Requirement of:Y2K International Standards USI Global StructureSOM*/Dept.40 Books10+chaptersTPD

11、in Quality System Structure Date:Apr.20,2000PlanDQAMQAVQASQATQA5 Milestone40 TaskGoal/ProcessSPCMCBManagement Manual:Updated and globalized QM+Gen.etc.(ADM/FD/MIS/Supporting Groups)Revise UpgradeMM(CorporateMM(Business/SitesSOM/Division or dept.TPD,ECN,Reports,etc.per product type.(0)(1)(2)(3)(4)(5)

12、(6)(7)1999 2000 Standard for International and Global(8)TQATQMBest ClassBest ClassINTERNALCEGEEXTERNALFEEDBACK/INTERNALFOLLOW UPTWHead Quarter.EXT.CUSTOMEROversea SiteRD/PM/P SITE INTERNAL ECNECR.CI.FOLLOW UP CI/ECN.Procedure,T.P.D,ECR,CI&ECN FLOWHQ DCSITE DCStandardization ImplementationSITE QRB/DC

13、QRBDCPMMM/TPDSOMTPD:Technical Product DocumentTPD:Technical Product Document 11NPI TPD Documentation NPI TPD Documentation 12Concept DesignDVTMVTEVT Mass ProductionStartPlanning EVT:Engineer Verification Test ,DVT:Design Verification Test ,MVT:Manufacturing Verification Test Pass Pass Pass Fail Fail

14、 Fail Gating Gating Gating 開發設計DevelopmentDesign 樣品製作Sample Build樣品評價VerificationValidation試產Pilot Run NPD NPINPD:New Product Development NPI:New Product Introduction Product Development Control Flow13What is EVT/DVT/MVT?Purpose:Increase Product Development Quality Reduce Risk of Development and Cos

15、t.EVT:Engineering Sample Verification Test -Early engineering sample meet product specification requirement without severity bugs,the sample may be made by mechanical mockup,earlier version hardware and software.-With small sample quantity,less test resource involvement,Key and critical test items t

16、o verify the sample.DVT:Design Readiness Verification Test -Design mature engineering sample meet product specification requirement without bugs,the sample should be tooling mechanical parts with near mature hardware and software.-With enough sample quantity,conduct all design test item to do verifi

17、cation to ensure product design readiness .14 MVT:Manufacturing Readiness Verification Test -Manufacturing quality level sample -Pilot run with small quantity manufacturing to come out optimization parameter for mass production -Conduct manufacturing point view verification with quantitative sample

18、to test product early life performance -Prepare parts for after service requirement -Got related regulation and certification for product -Ready for mass production What is EVT/DVT/MVT?15 Planning Requirement of Product Technology Feasibility,Business Feasibility Project Plan Specification(H/W,ID/Me

19、chanical,S/W,Regulation )Schedule Statement Of Work (Scope Of Work)PM,Team List Cost Sample plan Budget Customer Product Marketing Internal Capability External Supporting 16 Team member and ResponsibilityBU HeadPM(Project Manager)H/W(Hardware Design)S/W(Software Design)MD(Mechanical Design)PowerPCB

20、Layout EMCHomologationSafety Logo Certification Hardware FunctionTestCompatibility Function TestStability/Reliability TestMechanical TestPE(Product Engineer)Manufacturing ProcessManufacturing Testing Manufacturing Equipment Manufacturing QA PM:Owner to coordinate NPD operation PE:Owner to coordinate

21、 NPI operation NPD NPI Team list to have project member assignment from related function team 17Main Flow of Development Specification(H/W,Mechanical,S/W,Regulation )Schedule,Cost Product Design(Hardware)(Mechanical)(Software)Design Qualification Assurance(DQA)Design for Manufacturing(DFM)Design for

22、 Testing(DFT)Design for AvailabilityServiceability(DFA,DFS)Mass Production ManufacturingQualification Assurance(MQA)18Design Activity FlowDesign Design ReviewDesign Check List Simulation SpecificationRegulation Requirement EMCSafety ThermalDesignCheck ListDFMDFTDFADFSEMCSafety ThermalKnow How Experi

23、ence Approved19Design QualificationTest Plan SpecificationDesign Qualification Testing Bug Alerting and TrackingDesign Exit Gating Test Report20Design Qualification Plan for Server EVT 1.Hardware Function Test 2.BIOS Function Test 3.Intensive Test 4.Windows ME Function Test 5.Win NT/2000/XP Server F

24、unction Test 6.Server Management Test7.Power On/Off Boot up Test 8.Design Margin Test 9.Signal Quality Analysis 10.EMC Test 11.Thermal Test 12.Manufacturability analysis 13.MTBF PredictionDVT 1.Hardware Function Test 2.BIOS Function Test 3.Intensive Test 4.Win NT/2000/XP Server Function Test 5.Serve

25、r Management Test6.Server Stress Test 7.Sever Logo Pre Test 8.S/W,H/W Compatibility Test 9.Power On/Off Boot up Test 10.Design Margin Test 11.Signal Quality Analysis 12.EMC Test 13.Thermal Test 14.Acoustic Test 15.Vibration Test 16.Drop Test 17.Safety Test 18.Manufacturability analysis MVT 1.Hardwar

26、e Function Test 2.BIOS Function Test 3.Intensive Test 4.Win NT/2000/XP Server Function Test5.Server Management Test6.Server Stress Test 7.Sever Logo Pre Test 8.S/W,H/W Compatibility Test 9.Power On/Off Boot up Test 10.Design Margin Test 11.Signal Quality Analysis 12.EMC Test 13.Thermal Test 14.Acous

27、tic Test 15.Safety Test 16.Manufacturability analysis 17.Server Logo Submission 18.EMC Regulation Certification 19.ELP(Early Life Performance)Test 21Category of Design QualificationProduct SpecificationEnvironment StressRegulation/CertificationLife Performance 1.Hardware Function Test 2.BIOS Functio

28、n Test 3.Compatibility Test 4.OS Function Test 5.Signal Quality Analysis 6.Mechanical Thermal Test 1.ELP(Early Life Performance)Test 2.MTBF Test 1.Power On/Off Boot up Test 2.Design Margin Test 3.H/T/B Test 4.Thermal Cycling Test 5.Thermal Shock Test 6.Acoustic Test 7.Vibration Test 8.Mechanical Sho

29、ck Test 9.Drop Test 1.EMC Regulation Certification 2.Safety Regulation Certification 3.WHQL Logo Certification 4.Green PC Certification 5.Wi-Fi Certification 6.BQB Certification Manufacturing 1.Manufacturability analysis 2.Test Cover Analysis 22DFM(Design For Manufacturing)Quality,Cost RequirementUS

30、I and Supplier Process Requirement Easy Fabrication,Assembly Design Review(Design Rule,Check List,Lesson Learn)Early Involvement Bug Alerting and Tracking Shortest Cycle Time,Zero Failure Rate Cost Effective,Time To Volume RequirementProcess Target Special Fixture or Tooling Preparing Enough Design

31、Margin and Tolerance23DFT(Design For Testing)Quality,Cost Requirement Easy Testing,Enough Coverage 100%Test Coverage Early Involvement Shortest Cycle Time Cost Effective,Time To Volume Design Review(Design Rule,Check List,Lesson Learn)Bug Alerting and Tracking RequirementProcess Target Test Code,Spe

32、cial Fixture or Tooling Preparing24DFA(Design For Availability)Supply Risk Analysis Early Involvement Supplier ManagementBOM(Bill Of Material)Cost Effective,Time To Volume RequirementProcess Target Right Parts Selection Quality,Cost,Availability Requirement25DFS(Design For Serviceability)Design Revi

33、ew(Design Rule,Check List,Lesson Learn)Service Cost Analysis Early Involvement FRU Management PE Close Loop RecordHighest Customer Service SatisfactionRequirementProcess TargetEasy Handling,Lowest Service CostOn Time Service RequirementBug Alerting and Tracking26 Development DocumentationFG BOMProje

34、ct Folder MVT 32A2 Level BOMA1 Level BOMM/B H/W Design Output MVT 32S/W Design Output MVT 32BIOS Design Output DVT 21Mechanical Design Output MVT 32Product Folder AMOI MVT 31 BIOS MVT 32Schematic DVT 23PCB Layout MVT 31 Document BOM Material BOM 27Specification requirement Design Design Output Revie

35、w Sample fabrication Sample Qualification Test Report Design phase gating Bug tracking Sample debug and solution StartNext PhaseAction List Development Control operation Periodic Design Review28PDM Bug Tracking WorkflowOpenWorkAssignConfirmCloseAdd a defect.Fixing the defect RejectFail.Verify the fi

36、x&chooses either Pass or FailActionPass*DebugVerifyFailYesCancel (Any Time)By Supervisor or Originator ActionNo(A)(E)(E,D,C)(E)(C)(B)(B)29Solution Factor 30Severity level of Problem 31Design Phase Exiting Base on test plan to do Design Qualification Assurance Bug tracking management Base on the bug

37、severity and solution factor to judge phase exiting Base on the product maturity to judge to phase in mass production or lunch in market USI own product exiting control by QA and related Customer own product,maturity review by QA and got exiting from Customer.32 Lesson Learn Operation FlowProject De

38、velopmentEVT/DVT/MVT StartDesign Guide Check List Bug Tracking List Mass Production Lesson Learn Design stage,design team follow design guide or rule to conduct design.Design teams base on related check list to review and qualify design output to avoid same problem happen.Input bug to bug tracking s

39、ystem to conduct effective debugging Conducted lesson learn when project close or vital failure occur,base on bug list record and key experience to feedback into design guide ,check list to avoid making same failure and amplify advancement.After Service PE Close loop Collected after service PE close loop input and feedback into design activity.C.tw