1. From Research Prototype to Production
Felix Sanchez
Project Management
for ARA Engineers and Scientists

2. Desired Learning Objectives
Recognize what preplanning is required to take a product from Research to Prototype Item to Production Item
Understand and appreciate the time required to complete the checklist of items that must be considered in taking a Prototype to Production using VERTEK Division:
General items
Operational
Maintenance
System specification issues
Data requirements
Ecological and Disposability
Economic and cost considerations
Facility requirements
Training
Software
Safety reviews

3. From Research to Product
General Items
Is there a real need, and what size is it?
Are we using the “most appropriate” technology?
How many suppliers are available for critical technology items?
What are the risks and uncertainties?
What are the integrated system considerations?

4. From Research to Product
Operational Item Considerations
Has the product’s mission been defined?
Have the performance requirements been defined?
What are the technical performance measures?
What is the projected life cycle?
What are the environmental requirements in the following areas?
Thermal, Humidity, Shock, Noise
Storage, in stock and field
Transportation and handling
Have reliability requirements been established?
Installations procedures (who does)?
What are serviceability requirements?

5. From Research to Product
Maintenance Item Considerations
Have the maintenance levels been defined?
What are the organizational responsibilities for maintenance?
Test and support equipment requirements?
Software for diagnostics available?
What are the spare part requirements?
What are the repair/re-supply time requirements?

6. From Research to Product
System Specifications Available?
Have specifications been established?
Are there any conflicting specifications?
Materials
Performance
Power
Operability
Safety requirements
Reliability (including test and built in test)
Maintainability
Transport
Environmental
System integration (compatibility)
Optional items

7. From Research to Product
Data Requirements – does product documentation exist, including:
Circuit diagrams
Drawing package
Manuals
Training materials
Logistical support documents
Technical support documents
Bills of materials
Assembly instructions
QA test procedures and review lists
Are records required and are they subject to audit?

8. From Research to Product
Ecological and Disposability Considerations
Are any harmful materials present?
Are special procedures required at various points in life cycle?
Are transportation requirements established?
Labels required?

9. From Research to Product
Economic Considerations
Estimated material costs available?
Estimated pricing complete?
Market analysis/marketing plan complete?
Have all costs been considered over life cycle?
Variable
Fixed
Escalation
Shipping
Learning curves

10. From Research to Product
Facility Requirements Defined?
Operational
Tooling
Maintenance
Test
Training
Storage

11. From Research to Product
Training
Have operational and maintenance personnel requirements been defined?
Have training programs been established?
Is equipment required for training?

12. From Research to Product
Software
Have software requirements been defined?
Has software been documented?
Licensing considerations?
Has software been tested and verified on operational units?
Is maintenance software required?
Safety Review
Have all product reviews been conducted and documented?
Have all facility reviews been conducted and documented?

13. Prototype to Production
Engineering Team develops and builds a prototype that meets a set of specifications mandated by the customer
Engineering delivers the prototype to the Production Team. They also provide:
Rough Bill of Materials (BOM) with vendor information (i.e. what has to be procured?)
All schematics (hardware, boards, etc.)

14. Prototype to Production Process
VERTEK Engineering and Production Teams conduct kick-off meeting to begin technology transfer and documentation process, including final Bill of Materials and drawings
At VERTEK, the Program Manager is in charge of both Prototype development and production of final product
The PM assigns a Task PM who is in charge of developing and building the Prototype
The Task PM (AKA: Technical Lead, Task Lead, Control Account Manager)
Has budgetary and technical responsibility for the
R&D effort that ends in prototype delivery and
acceptance by the customer

15. Prototype to Production
Prototype is considered the baseline product
All changes made from this point forward are completed via an approved Engineering Change Request/Engineering Change Notice (ECR/ECN) process
Both the PM and Technical Lead must sign off on all ECRs and ECNs
The PM evaluates ECR impact to overall program (cost, schedule, fleet configuration)
Technical Lead evaluates ECR for technical
impact to product and assures product
continues to meet technical specifications

16. Prototype to Production
Production evaluates prototype for:
Manufacturability
Vendor’s qualified
Scheduling production run
Personnel requirements
Equipment/Fabrication requirements
ID QC points along production

17. Prototype to Production
Procurement of components begins and Work Orders are released
PM and Team Leader validate vendor products
QA Department performs incoming inspection of key vendor parts (PCB, power supplies, etc.)
All manufacturing, electrical, fabrication and final assembly is completed
Final QA is performed
Product is prepared for shipment

18. Wrong Way to Do It

19. Right Way to Do It

20. VERTEK staff always available for your consultation
Summary
Thorough preplanning is required to take a product from Research to Prototype Item to Production Item
You must engage VERTEK Division early – before the proposal phase – to ensure a great product for customer and ARA
VERTEK staff always available for your consultation