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

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

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?

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?

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?

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

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?

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?

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

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

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

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?

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.)

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

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

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

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

Wrong Way to Do It

Right Way to Do It

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