New Product Development

NPD(新產品開發流程)
第二組
指導教授：謝焸君
團隊成員：0000
鄭美芳、江寶焜
李岳桓、陳炫穎
黃志揚、陸聰文
 為何需要新產品開發與流程 ??
(動機說明)
 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,縮短
開發時間,使產品快速上市,以取得最佳利潤 .
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 問題

沒有整合的產品開發流程，部門之間的合作有如多頭馬車。

www.company.com
 解決方案 – 讓所有人說一樣的話

Electronic
BIOS
POWER Hardware
S/W
F/W
PCB
Pre_Load
Layout
Simulation
Mechanical
EMC/Safety ID
Product
Thermal
Design
Design
Publication Capability

Reliability
Product Testing
Engineering
Compatibility
Testing Testing Testing
Manufacturing Fixture
Program
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 Life Cycle of Product

市場
Marketing 企劃
Planning
終止
End of Life
開發設計
Design
量產
Mass Production
試作 / Sample
試產 評價 / Evaluation
Pilot Run

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 New Product Development Control Flow
Start

Planning Key
Terminate
Events
Charter
Pass
NPI
Concept Design
EVT
Development Sample
Fail Gating
Terminate Design Verification & Build

NPD Pass Validation

DVT
Regulation &
Fail Terminate
Gating Certification
Pass

MVT Pilot Run

Fail Gating Terminate
Pass
NPI : New Product Introduction
Mass Production EVT : Engineer Verification Test
DVT : Design Verification Test
End
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MVT : Manufacturing Verification Test
 NPD / NPI

ODM Project OEM Project

• NPI : New Product
Introduction
NPI is a process to transfer
NPD NPI design results from the
NPI development team of UXX /
Operation
Operation Operation customer into mass production
through sample builds and pilot
run activities.
• NPD : New Product
NPD
Fail Development
Gating
Phase
Pass Besides the NPI activities , It
also included product design and
Mass Production design verification and validation
related activities .
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 OEM / ODM / JDM / OBM Business operation

• OEM ( Original Equipment Manufacturing ), Design is done by the

customer, UXX provides manufacturing service only. UXX’s participation is
limited to Sample build, Pilot Run, and mass production .

• ODM ( Original Design Manufacturing ), UXX provides all services of the

NPD processes starting with the Concept Phase and taking it to mass
production. Planning phase participation will depend on product ownership.
UXX will drive the Planning activities if it has ownership of the product.
Otherwise the customer will drive the Planning activities .

• JDM ( Joint Design Manufacturing ), Besides the service of OEM, the

development process is jointly owned by both UXX and the customer. Roles
and responsibilities will be based on mutual agreements between the two
parties .
• OBM ( Own Branding Manufacturing ), UXX owns all phases of the NPD
process plus sales, marketing, distribution , and service to end of life .
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 Project phase and business model
Start
ODM/OBM OEM JDM
Planning
V O
Terminate
Charter
Pass
Concept Design
V O
EVT
Fail Terminate
Gating
Pass
DVT V V V
Fail Terminate
Gating
Pass

MVT V V V
Fail Gating Terminate
Pass
Mass Production V V V

End
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V : Must , O : Option
 Project Type and phase

Project Type
Extension project
New Refresh
- Package design change, no
Extension
product design change.
Concept Design Beginning Beginning
V Approve Approve
- Country configuration EVT by RD by PE
Head Head
extension, no related to DVT V V
product design modification.
- The other type after
MVT V V V

discussion and agree belong

Mass Production V V V
to extension type project.
Refresh project
- Product design modification not on core function.
- S/W design change, without H/W design change.
- Same H/W design, Core parts feature up or down grade. System product,
commodity (ex. CD-ROM, HDD, LCD panel and so on) change.
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- The other type after discussion and agree belong to refresh type project.
 Planning
Customer / Market requirement

Business Feasibility
Business Plan , Product Requirement Document

• Internal Capability
Technology Feasibility
• External Supporting

Project Plan

 Specification ( H/W , ID/ Mechanical , S/W , Regulation … )

 Schedule
 Statement Of Work ( Scope Of Work )
 TPM , Team List
 Cost and cost development
 Sample plan ( for debugging , DQA test , promotion … )
 Budget
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 Team member and Responsibility
BG / BU Head

PM PM : Product line operation owner

( Product Manager )
BPM TPM
( Business Program Manager ) ( Technical Project Manager )
BPM : Coordinating commercial ,
logistics and fulfillment
operation

H/W S/W MD Power

( Hardware Design ) ( Software Design ) ( Mechanical Design ) PCB Layout

EMC Stability / Reliability

Safety Logo Certification
Homologation Test

Hardware Function Compatibility Material Procurement

After Service
Test Function Test VQA
NPI

PE Manufacturing Manufacturing Manufacturing Manufacturing

( Product Engineer ) Process Testing Equipment MQA
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TPM : Coordinating NPD design / development operation PE : Coordinating NPI
operation
 Activities, Ownership in Product Life
Cycle
PM : Product Manager

Activities
NPI – PE
NPD – TPM Product Engineer Fulfillment – BPM
Technical Project Manager Business Program Manager

NPD
Manufacturin
NPI g
Engineering Timing

Planning Concept DVT MVT Mass End of Life

Design
Production management
Kick off EVT
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 Project Job Handover
Gating Gating Gating

EVT DVT MVT Mass

productio
n
NPD , Design team  PE team Design team support

PE , put NPD Data  NPI TPM  PE PE

TPM coordinating
NPD operation
PE team early involvement as
PE Head as gating approval PE take over project ,
NPD job definition
PE start to take over project design issue support by RD

NPI , PE team  MT team

PE , MT team put data into NPI operation PE  MT (ME,TE) MT (ME,TE)

MT coordinating NPI
operation
MT team early manufacturing
MT Head as gating approver
involvement
PD take over responsibility
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 Project Plan Working Concept

Specification
Cost
Delivery EVT / DVT / MVT

Development
Design
MM BG NPD
Chapter control flow Project Plan Verification &
SOM Validation

Regulation &
Certification
Product
NPI operation
DQA Test
Guideline
SOM ( DQA )

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 Project Task Assignment and Control
Assign task at phase beginning , Forward & Control by PDM
Assignment in phase beginning !! Operation , attachment , input !!

Document Collection
Project Put document
Output document in On PDM project
Plan
PDM , assign by DCN Folder
document box setup
/
Task assignment
NPI Put result on
Operation No output document Action Tracking
Plan task assign by Action Column
Tracking flow in PDM

Bug tracking
PDM : Product Data Management
operation
DCN : Document Change Notice
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 Project Charter
PDM database structure for project operation
Project Owner be assigned for the
Project NPD/NPI management
Project Life Control

Project Owner prepare Project

plan and be approved by BG/BU Bug tracking
Head

PDM Project Life control

Project folder
request
Kick off meeting , Project brief NPD Folder

NPI Folder
Project phase plan be forwarded
by PDM Material BOM

Project operation
Project Life Control is the mother database to record
project life information and as a flag to control project
www.company.com related database creation .
 Project Kick Off

TPM , Team up by BG NPD SOM define ,

Engineer be assigned from function team

PM , TPM/BPM call meeting for Project

brief
1. Project Plan brief
2. Experience sharing
3. Team member input

Meeting minutes sharing , put on PDM

Project phase plan be forwarded by PDM

Project operation

Understanding , Early involvement

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 Concept design & EVT
• Concept Design :
- Define major subsystem and interface
Planning - ID (Industry design) design
- Identify key parts supplier
Yes - Define final assembly scheme
Jump to Detail design ??
> Conditions of jumping to detail design
No
- Design team experience
- Design scale
Concept Design
( System level Design ) • EVT : Engineering Sample Verification Test
- To verify the initial design by producing
limited quantity of prototype for functional
EVT design verifications
( Detail Design )
- EVT must be completed with no fatal failure
( Sample build )
( Debug ) and meeting the majority of the product
( Verification ) specifications
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 EVT Major Activities

Detail design major activities ,

- Mechanical detail structure and parts design
- Electronic detail circuit design, parts selection and PCB board design
- Software design and coding
- Process design
- Test plan for EVT, DVT and MVT
The other major activities ,
- DFM / DFT early involvement , EVT sample built
- EVT verification test
- Bug / deviation tracking and fixing
- Mechanical mold tooling design and feasibility study
- Preliminary parts approve test
- Parts risk analysis
- www.company.com
Regulatory certification preliminary test
 DVT

• DVT : Design Readiness Verification Test

- The design output of DVT shall meet all specifications and requirements
- It must pass all verification tests and appropriate validation tests to
achieve design readiness to proceed to MVT
• The major activities are ,
- Design modification
- DFM / DFT early involvement , DVT sample built
- DVT verification test and validation test
- Bug / deviation tracking and fixing
- Mechanical mold tooling fabrication and try-run
- Parts approval test
- Golden candidate of software design
- Package design
- Regulatory certification test
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Parts supply risk management, Procurement of long lead time parts
 MVT
• MVT : Manufacturing Readiness Verification Test
- Validation testing of final customer shippable hardware and software
along with manufacturing readiness review ; Yield rate study is also done
here to determine optimum manufacturing parameter for ramp up to meet
time to volume requirement.
- The major activities are:
> Pilot run and yield rate improvement
> MVT validation test, Regression verification test when needed
> Bug/deviation tracking and fixing > Golden version software design
> Mechanical mold tooling approval > Obtain regulatory certification
> Fixture and test program finalization
> NPI TPD document and file release
> Quality control plan
> After service related preparing
> The other requirement of 4M for manufacturing preparing
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( 4M : Man , Material , Machine , Method )
 Main Flow of Product Development
Specification ( H/W , Mechanical , S/W , Regulation … )
Schedule , Cost

Design for Design for

Availability ( DFA ) Product Manufacturing
Design ( DFM )
Design for
Serviceability ( Hardware )
( DFS ) ( Mechanical ) Design for
( Software ) Test ( DFT )
Design
Qualification
Assurance ( DQA ) Manufacturing
Quality
Assurance
Mass Production
( MQA )
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Concurrent Engineering !!
 Design Activity Flow

Design DFM DFA

Simulation
Check List DFT DFS

Specification
Design
Design Approved
Review
Design
Guideline

EMC EMC
Regulation Design
Safety Safety
Requirement Check List
Thermal Thermal

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 Design Qualification Assurance (DQA)
Specification

Test Plan Product DQA Test Guideline SOM

Design Qualification Testing (DQA)

Bug Alerting and Tracking

Test Report

Design Exit Gating

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 Design Qualification Test Plan for Desktop PC
EVT
1. Hardware Function Test
2. BIOS Function Test
3. Intensive Test
4. Windows ME/2000/XP Function Test
5. Linux Verification Test
6. Power On/Off Boot up Test
7. Design Margin Test
8. Signal Quality Analysis
9. Audio Precision Test
10. EMC Test
11. Thermal Test
12. Manufacturability analysis
13. MTBF Prediction
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DVT
1. Hardware Function Test
2. BIOS Function Test
3. Intensive Test
4. Windows ME/2000/XP Function Test
5. Linux Verification Test
6. Windows Logo Pre-Test
7. S/W , H/W Compatibility Test
8. Power On/Off Boot up Test
9. Design Margin Test
10. Signal Quality Analysis
11. Audio Precision Test
12. EMC Test
13. Thermal Test
14. Acoustic Test
15. Vibration Test
16. Drop Test
17. Safety Test
18. ELP1( Early Life Performance ) Test
19. Manufacturability analysis
MVT
1. Windows Logo Submission
2. EMC Regulation Certification
3. Safety Regulation Certification
4. Preload test
5. ELP2( Early Life Performance ) Test
6. Regression test ( If needed )
- Hardware Function Test
- BIOS Function Test
- Intensive Test
- Windows ME/2000/XP Function Test
- Linux Verification Test
- Windows Logo Pre-Test
- S/W , H/W Compatibility Test
- Power On/Off Boot up Test
- Design Margin Test
- Signal Quality Analysis
- Audio Precision Test
- Thermal Test
- Acoustic Test
- Manufacturability analysis
 Verification , Validation Test

• Verification test
It is conducted to verify the output meet input requirement in
EVT and DVT phase, regression verification test is conducted when
MVT output still has issues being able to meet input requirement
( For example – Function test , EMC Test , design margin test …. )

• Validation test
It is conducted to ensure that resulting product meets customer
requirement for specified application usage or market end user
intended use in DVT and MVT
( For example – ELP test , MTBF test )

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 NPI ( New Product Introduction )
Project Charter

Plan and kick-off – Quality / Cost / Delivery / service

NPI operation coordination , Design input , Quality requirement

MFG Process , test development , DFM/DFT Early involvement
Material purchasing / Cost / Supplier management , DFA / VQA
Material evaluation / Second source alternative
Logistic management and Sample build
Customer service , DFS
SFIS (Shop Floor Information System) , Bug tracking system
Engineering change management (ECN/ECR/ECR-Design)
TPD document creation and management
MFG Quality control / Customer Quality Criteria

Fail Pass
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 NPI Operation Flow
Project charter and Kick off

NPI Operation Plan Control by PDM

Coordinator, MFG MFG Material Material After MFG

Get design Process, Testing preparation control , service Quality
output data Equipment And DFA DFA And Control
Input and DFM DFT VQA Sample DFS
Build
PE / MD ME / EQ TE MP/VQA/CE PC/MC/HW/PD CS MQA

- Parts - MFG Process - AOI program - BOM cost - MFG booking - WW service - Quality Plan
creation development - ICT fixture - Risk parts - MFG site planning - CSA test
- BOM creation - Equipment and management Scheduling - FRU parts - Customer
- H/W, S/W, setup and program - Material - Material MFG and quality
Test code, program - FCT fixture purchasing control and delivery requirement
Mechanical - MFG MOI and program -Supplier and keeping - Test fixture - Quality
data input - Stencil - Test MOI AVL, AML - Training and preparation control
- Quality - MFG Fixture, - Material certification - Repair - Lesson learn
requirement - Jig, Carrier evaluation - Sample build engineer collection
- Coordination AMPL training

Sample Build SFIS Failure collection and Bug

Tracking
No
Pass Phase Gating Review
Yes
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Next Phase
 DFM ( Design For Manufacturing )
Requirement

Quality , Cost Requirement

UXX and Supplier Process Requirement

Early Involvement Bug Alerting and Tracking

Design Review ( Design Rule,Check List,Lesson Learn )
Process

Enough Design Margin and Tolerance

Special Fixture or Tooling Preparing
Process Development , MOI , Equipment purchasing

Easy Fabrication , Assembly

Target

Shortest Cycle Time , Zero Failure Rate

Cost Effective , Time To Volume
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 DFT ( Design For Test )
Requirement

Quality , Cost Requirement

100% Test Coverage

Early Involvement Bug Alerting and Tracking

Process

Design Review ( Design Rule,Check List,Lesson Learn )

Test Coverage and Backup Solution
Test Program , MOI , Fixture or Tooling Preparing

Easy Testing , Enough Coverage

Target

Shortest Cycle Time

Cost Effective , Time To Volume
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 Coverage of Testing
Start

Planar SMT Process

AOI ( Automation Optical Inspection )

Parts Planar PTH Process RD Design cycle

within
Test
Coverage ICT ( In Circuit Test ) test DFT
Check List
FCT ( Functional Test ) test
Or
/
The other test solution Design Guideline

Parts out
of Test Backup plan and Solution Lesson
Coverage www.company.com Learn
 SFIS Control for PCBA
SAP
SFIS ( Shop Floor Information System )
W/O
SFIS
SMT AOI ASM
PDM PM

BOM •SN Range Input •AOI Test Result •SN Barcode

Send to SFIS DB Scan
ECN •SN Label
Printing •Pass/Fail

Packing FCT ICT

•SN/Carton/Pallet No •FCT Test result send to

•ICT Test result
mapping SFIS DB
send to SFIS DB
•Carton/Pallet Label Printing •Check MAC

FQC SHIPPING

•Record Sampling SN •SN/Delivery No mapping

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•Check Model/Qty
 AVL / AML , Core Supplier
Vendor

VQA Maintenance

Regular Vendor Qualified Vendor

Approved Vendor List (AVL)
BOM operation focus

Parts selection focus, Manufacturer Agent

Have it in SAP
system,
VQA Maintenance
Qualified Manufacturer Regular Manufacturer
Approved Mfg’r Vendor (AML)
Purchasing focus Partner,
MP team periodic provide
list
Core Supplier
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 AML List Maintenance
Start

ENPD Parts Creation AML Database

AML database query

No
New MFGer ENPD Parts Creation
Yes

No
MP agree Not new parts trigging
Yes New Vendor Survey

VQA – Vendor Survey

AML / AVL Approval AML Database

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END
 Material Approval Status and AMPL
Start

Initial

DQA Test
CE test Review
Batch Test
3rd party Lab. Test Document
Matrix Build Test

Project Customer
CE Approval Obsolete
Approval Assignment

For the For the

AMPL Database Phase Out
Project only Project only
Partial Approval for Grouping parts
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AMPL : Approved Manufacturer Parts List
 Sample Build ( EVT – MVT )

Start Material Preparation

( MP,BD,RD,PE )
MFG Booking ( BD  PC )
Material Control
( MC,WH )
Re-Schedule

No
Material Ready
Status Review

Yes
MFG Engineering (MT,PE,RD)

MFG Quality Control ( MQA ) Sample Build ( PD )

MFG Scheduling ( PC )

Sample UXX
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internal delivery
 Development Operation Flow

Specification requirement Start

Design ECN / ECR / ECR – Design

Action Tracking
Design Output Review

Periodic Design Review

Sample build

Sample debug and solution

Sample Qualification Test

Bug tracking
Test Report

Design phase gating Next Phase

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 Severity level of Bug

Severity level Description

1 Critical User cannot continue.
Unable to proceed with major portion of test or development,
and / or defect causes a major checkpoint to slip day-by-day,
and / or the customer is halted. Immediate fix is needed.
2 Serious User severely restricted.
Test or customer is severely restricted due to a defect
encountered for which there is no acceptable workaround.
3 Problem User not severely restricted.
Able to proceed with limited function which not crucial to test or
development. Either the defect is serious but an acceptable
circumvention exists, or the defect is not a serious
4 Minor Slight hindrance for user.
No immediate impact to test or customer. Cosmetic problem
with no functional impact.
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 Solution Factor

Coding Solution Description

A Solution introduced industrially by - "Yes"

B Solution introduced industrially by - "No" , Evaluated by - "Yes"

C Evaluated by - "No" , Solution known - "Yes"

D Solution known - "No" , Cause known - "Yes"

E Cause known - "No"

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 NPD Phase Operation
TPM Assign Phase Task at phase beginning , Forward & Control by PDM

SOW of Phase Operation Plan of Project Plan ECR-Design

Beginning Task - ( NPD project folder attachment ) A

P
Task - ( Action ) C
B R
T
U O
I
Engineer follow assignment Operation & Attachment G J
O
E
Design N
T C
Operation
DFM/T/A/S Early Manufacturing Involvement R T
T
A
R
Design Quality Assurance (DQA) C F
A
K O
C
I L
K
Bug / Deviation ( Bug Tracking ) N D
I
G E
Ending Plan result (Project Folder Data Attachment , Action Tracking) N
R
G
KPI of Phase
Phase Gating Review to Exit
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ECN / ECR
 ODM Project Operation Gating
ODM/JDM Project EVT DVT MVT Mass Production
Project Owner TPM ( Technical Project Manager ) BU Assignment
Fulfillment BPM ( Business Program Manager ) BPM
NPD/NPI Function Base on project plan team list assignment
Gating Trigger TPM ( Technical Project Manager ) Project Owner
Gating Approval RD Head PE Head MT Head Site MT Head
NPI coordinator PE PE ME ME
NPI Technical Support RD RD PE,RD PE
NPI Issue Reviewer ME,TE,MQA ME,TE,PD,MQA
NPD coordinator TPM TPM TPM PE
NPD Technical Owner RD RD RD
NPD Issue Reviewer DQD DQD,QE DQD,QE
NPI Issue reviewer responsibility :
1. MDE,TE to review the input qulity from PE
2. MQA review PE and MT team operation follow NPI SOM defintion and by customer point
view to review related MFG activity and preparation
3. Mass Production is World Wide MFG Site Product Transfer
NPD Issue reviewer responsibility :
DQD and QE team follow DQA test guideline SOM to qualify product design quality
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 ODM Project Phase Gating

Kick off NPD : DQD , QE

NPD: DQD RD Head NPI : ME,TE,MQA PE Head

Pass Pass
gating Pass gating gating Pass
EVT reviewer
gating
approver
DVT reviewer approver

reject reject
reject reject

NPD : DQD , QE
NPI : ME,TE,PD,MQA MT Head

gating Pass gating Pass Mass

MVT reviewer approver Production

reject reject

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Thank you