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PRODUCT DEVELOPMENT BEST PRACTICES AND ASSESSMENT Kenneth Crow DRM Associates
© 2001 DRM ASSOCIATES BEST PRACTICES CATEGORIES TITLE Management leadership (11) Early involvement (9) Product develop- ment teams (12) Organizational environment (11) Process management (11) Process improvement (8) Customer orientation (6) Requirements & speci- fications management (9) Development process integration (7) Supplier/subcontractor integration (7) Transition to produc- tion (6) Configuration management (9) Design assurance (9) Project & resource management (10) Product data (10) Design automation (12) Simulation and analysis (9) Computer-aided manufacturing (6) Support technology (7) Knowledge organi- zation (4) Business & product strategy (5) Product planning & management (11) Technology management (10) Design for manufac- turability (12) Product cost management (12) Robust design (14) Design for testability (14) Design for operation & support (12) Strategy (26) Organization (45) Process (82) Technology (48) ( ) Number of best practices / questions Design Opti- mization (60)
© 2001 DRM ASSOCIATES BEST PRACTICE SOURCES Workshops & Meetings Telephone Discussions Literature Review BMP Program Conferences Consulting Experience Company Visits Technology Vendors Corporate Handbooks Panel of Experts BEST PRACTICES
© 2001 DRM ASSOCIATES BEST PRACTICES Became the basis for a product development assessment methodology Multi-year effort by consortium to identify best practices of product development Consortium led by DRM Associates Effort involved: -On-site visits to top companies -Research and attendance at over 100 conferences & meetings
© 2001 DRM ASSOCIATES IMPROVING PRODUCT DEVELOPMENT How well are we doing? What improvements are needed? Where do we start? Should we benchmark? Product planning Integrated product teams Design for manufacturability Project planning Requirements definition Resource management Solids modeling Product data management Configuration management QFD Early involvement Analysis & simulation Early supplier involvement Empowerment Design re-use Top-down design MCAD CAE The Product Development Best Practices and Assessment software and methodology provide an objective way for identifying opportunities and planning improvements
© 2001 DRM ASSOCIATES Benchmark the company’s product development process against best practices and industry performance Determine the extent that new product development best practices are being utilized Identify high-payoff improvement opportunities for improvement Establish a metric to measure progress in improving product development WHY DO AN ASSESSMENT
© 2001 DRM ASSOCIATES DEVELOPING AN IMPROVEMENT PLAN Business Strategy (Strategic Levers) GAP CURRENT SITUATION BEST PRACTICES IMPROVEMENT PLAN Product Development Assessment 3.Develop a plan to close gap 1.Assess current situation 2.Determine priorities based on strategy & Best Practices What’s possible What’s important What the weaknesses are
© 2001 DRM ASSOCIATES BEST PRACTICES AND ASSESSMENT Best practice statements & assess- ment questions Performance relative to criteria/ question Importance of each criteria to the organization Description of evolution towards best practices to aid evaluation Assessment worksheets provides structure & a framework for feedback
© 2001 DRM ASSOCIATES BEST PRACTICES AND ASSESSMENT Assessment worksheets for each of the 28 categories Summary performance for the category
© 2001 DRM ASSOCIATES SUMMARY & GAP ANALYSIS Summary effectiveness Category weight & effectiveness
© 2001 DRM ASSOCIATES SUMMARY & GAP ANALYSIS Gap analysis identifies high payback areas of improvement
© 2001 DRM ASSOCIATES PRODUCT DEVELOPMENT STRATEGIES Product Development Strategic Objectives: Time to market /development schedule Low development cost Low product cost High product innovation and performance Quality, reliability and dependability (robustness) Service, responsiveness & flexibility to respond to new product opportunities & markets An organization cannot do everything superbly. It must focus on only one or two strategic objectives and be competent in the other areas.
© 2001 DRM ASSOCIATES STRATEGIC LEVERS Strategic levers are best practices which have a major impact on achieving a product development strategy. Best practices are associated with strategies through a relationship factor of 0 (insignificant impact on strategy) to 3 (major impact on strategy) to assess strategic alignment. Strategic levers
© 2001 DRM ASSOCIATES TIME-TO-MARKET STRATEGIC LEVERS 2.3Prioritize development projects 2.7Don’t overload resources 5.4Rapidly staff the project according to plan 8.9Emphasize design re-use to minimize development cost & schedule 11.4Capture and document requirements and specifications completely 11.8Tightly manage requirements 12.3Plan concurrent development 12.4Tightly synchronize development activities 12.5Learn to work with partial information 12.7Prepare to roll out the product early 13.1Involve subcontractors and suppliers in development 14.2Plan and coordinate production requirements 14.6Resolve production problems quickly 17.2Create a comprehensive, realistic project plan
© 2001 DRM ASSOCIATES TIME-TO-MARKET STRATEGIC LEVERS 17.3Obtain personnel's commitment to the project plan 17.4Communicate project plans and responsibilities 17.4Identify project staffing requirements 17.6Plan development resource requirements 17.7Allocate and manage resources 18.9Use modular design approach 18.10Standardize parts and materials 21.13Balance testing and time-to-market considerations 24.4Create electronic mock-up of the product 25.2Simulate & analyze product designs early to minimize late iteration and physical prototypes. 25.5Tightly integrate analysis & simulation with design 26.1Use rapid prototyping technologies 27.1Use collaboration systems to facilitate communication
© 2001 DRM ASSOCIATES STRATEGIC ALIGNMENT High strategy ranking suggests that performance level of related practices should be higher than performance level of practices related to lower ranked strategies Positive gap suggests that practices related to this strategy require improvement; negative gap indicates over-emphasis on lower priority practices
© 2001 DRM ASSOCIATES EVALUATION FRAMEWORK Performance Evaluation010 Best Practice Industry Performance Database Company Performance Database to compare company performance against
© 2001 DRM ASSOCIATES DEVELOPING THE ACTION PLAN 1.Identify performance gaps relative to categories 2.Identify strategy gaps and associated practices 3.Examine individual practices with low performance & high importance in large gap categories & strategies 4.Look for logical relationships & precedence among practices 5.Develop the action plan & gain consensus to the plan Task 1 Task 2 Task 3 Task 4 Plan
© 2001 DRM ASSOCIATES ACTION / IMPROVEMENT PLAN Based on the gap analysis, put together a plan for improvement
© 2001 DRM ASSOCIATES THREE OPTIONS FOR AN ASSESSMENT 1.Consultant-led assessment –Greater objectivity and frame of reference –Overcomes organizational politics –Expertise in quickly identifying issues and planning improvements 2.Self-assessment using the Product Development Best Practices and Assessment (PDBPA) software –Inexpensive 3.Assessment workshop (2-3 day) –Compromise with expense, yet provides oversight and guidance for planning improvements
© 2001 DRM ASSOCIATES CONSULTANT ASSESSMENT PROCESS Preparation Preliminary data collection Information review Interview scheduling Fact-Finding Interviews -Individual -Group/ team Walk-throughs Data gathering Follow-up & clarification Evaluation Preparation of findings Preliminary evaluation Discussion & final evalua- tion Recommen- dations & priorities Preliminary action plan Presentation Group presentation & discussion Follow-up discussion Implementa- tion planning Implementation Detailed planning Project organization Reengineering Implemen- tation & improvement Training and deployment 1-3 days3-20 days1-5 days1-4 daysTBD
© 2001 DRM ASSOCIATES DELIVERABLES FINDINGS - Design Assurance Have not effectively integrated customer personnel in IPT’s and moved to incremental design reviews –Traditional reviews with hundreds of customer personnel Controversy over whether product assurance should be part of the IPT or remain an independent function –Combination of both approaches needed –Quality engineering and reliability engineering resource should be provided to support the IPT’s and budgeted by the IPT’s –A central product assurance function is also needed While a “mini-” FRACAS system established, there has been inadequate emphasis on this tool and it may not be robust enough to meet future needs General culture appears to be reactive to design assurance problems rather than proactive Concern over how vendor off-the-shelf hardware is specified and how requirements are incorporated that are beyond the vendor spec. RECOMMENDATIONS Fine-tune organization structure –Define composition, roles and responsibilities of the Program Management Team –Move toward a combination of “top down” and “bottom-up” integration responsibilities with WSEIT, Integration Teams & IPT’s –Expand role of Missile Systems Integration group to include assembly modeling, assembly planning, and assembly process; include Courtland personnel as formal members of this team –Work with TPO to better align the two organizations structures and TPO involvement of IPT’s Better define F&R’s of teams and functional groups. Review team charters, once established, against F&R’s to insure no holes, minimal redundancy, and effective integration Establish well-defined boundary conditions for each team Best Practices assessment templates Assessment summary & gap analysis Action Plan Findings for each category Priority recommendations
© 2001 DRM ASSOCIATES CONSULTANT ASSESSMENT BENEFITS Objectivity & consistency for comparison of effectiveness ratings More efficient use of company resources Comprehensive assessment report includes: –Assessment worksheets & summary –Detailed findings –Detailed recommendations & action plan Perspective & expertise to develop action plan Debriefing and discussion of opportunities
© 2001 DRM ASSOCIATES ASSESSMENT WORKSHOP Assessment done in a 2- to 3-day workshop involving key people Best practice templates completed; findigs noted on flip chart Upon completion, gain consensus and plan improvement actions Consultant participation to: –Discuss issues and answer questions –Capture information –Help with and validate assessment –Assist in developing an action plan - suggest priorities & help package needed actions into projects
© 2001 DRM ASSOCIATES PDBPA SELF-ASSESSMENT SOFTWARE MS Excel application (Windows 95, Windows NT and Macintosh) includes: –Instructions –Best practices and assessment questions –Evaluation scale & description of evolution towards best practices –Strategic alignment analysis –Performance summary and gap analysis Decide who needs to provide input or complete assessment sections Process takes one knowledgeable person approximately 8 hours to complete Different people can assess each section or multiple assessment inputs can be averaged Upon completion, the company mails a copy of the diskette back for updating the industry performance database and comparison with industry performance
© 2001 DRM ASSOCIATES CASE STUDY - 1 $100 million medical equipment company Many development projects and limited resources Very positive culture and management Active efforts to implement concurrent engineering Wanted to determine how well they were doing and what steps should undertaken next
© 2001 DRM ASSOCIATES CASE STUDY - 1 Need 1 - Project prioritization & resource mgt. Need 3 - Infrastructure to access product model & PDM System Need 2 - Earlier involve- ment of support functions
© 2001 DRM ASSOCIATES FINDINGS & RECOMMENDATIONS Outstanding company culture and environment conducive to teams Most significant issue was product planning and managing resources Too many projects in process at any time Resources over-committed, delaying projects Inhibited effective early involvement of support functions on teams Needed improved product planning process to prioritize projects, strategy of undertaking fewer projects, and implementing a resource management system in conjunction with project planning Continued effort required to expand number of CAD workstations and create infrastructure to access digital product model Needed to move away from managing paper to managing digital information with PDM system PDBPA provided an objective basis for planning improvement activities & identified the product planning/resource management issue that the company was not aware of
© 2001 DRM ASSOCIATES CASE STUDY - 2 Defense contractor, $600 million development program Thought the company was “doing concurrent engineering”, but little real experience with teams & very traditional management Customer wanted “integrated product & process development (IPPD)” approach Management perceived problems with the “structure” of the teams Significant budget shortfall required a different approach & forced budget cuts
© 2001 DRM ASSOCIATES CASE STUDY - 2 Need 2 - Common, defined process Need 3 - PDM System Need 1 -Teams & empowerment
© 2001 DRM ASSOCIATES FINDINGS & RECOMMENDATIONS While programs were well-managed, concurrent engineering was minimally applied The “structure” problems with teams were the result of management attempting to create functional stovepipe organizations within a team environment Major issue was the authoritarian management style and lack of empowerment Customer personnel’s lack of understanding of IPPD also hindered the effectiveness of teams Issue of who should fund team training - the enterprise or the program? Total lack of understanding & focus on business processes Budget shortfall resulted in significant cut in configuration management - only solution to achieve budget & maintain control was to implement a product data management system
© 2001 DRM ASSOCIATES SUMMARY Companies need continuing effort to improve product development practices and process A product development strategy needs to be explicitly defined Product development practices and process need to be aligned with strategic objectives Benchmarking & best practice databases aid identification of best practices A self-critical approach and competitive imperative are needed as a basis for significant improvement Improvement efforts should be focused on areas that will have the greatest payback Improvement efforts should address organization, process and technology in a balanced way
© 2001 DRM ASSOCIATES PRODUCT DEVELOPMENT BEST PRACTICES & ASSESSMENT If you would like more information on: Integrated Product Development Product Development Best Practices and Assessment Software Product Development Consulting & Training Please contact: Kenneth Crow DRM Associates 2613 Via Olivera Palos Verdes, CA (310) ; Fax (310) Product Development Best Practices and Assessment © 2002 DRM Associates
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