1. New Product Development NPD(新產品開發流程) 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 第二組

2. www.company.com 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. (動機說明)

3. www.company.com 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。

4. www.company.com 解決方案 – 讓所有人說一樣的話 Product Design Capability POWER Publication Product Engineering Thermal Design Mechanical ID BIOS S/W F/W Electronic Hardware Reliability Testing Compatibility Testing Program Testing Fixture PCB Layout Simulation Pre_Load Manufacturing EMC/Safety

5. www.company.com Life 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 Production

6. www.company.com New Product Development Control Flow NPI : New Product Introduction EVT : Engineer Verification Test DVT : Design Verification Test MVT : Manufacturing Verification Test Development Design Verification & Validation Regulation & Certification Key Events Concept Design DVT MVT EVT Mass Production Start Planning Pass Fail Gating NPD End Terminate Charter Terminate Pass Pilot Run NPI Sample Build

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

8. www.company.com 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.

9. www.company.com Project phase and business model Concept Design DVT MVT EVT Mass Production Start Planning Pass Fail Gating End Terminate Charter Terminate Pass V ODM/OBM OEM JDM V V V V V V V O V V V V : Must, O : Option O

10. www.company.com Project Type and phase Concept Design DVT MVT EVT Mass Production V Project Type New Refresh Extension V V V V V V V V Beginning Approve by RD Head Beginning Approve by PE Head 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. - The other type after discussion and agree belong to refresh type project. Extension project - Package design change, no product design change. - Country configuration extension, no related to product design modification. - The other type after discussion and agree belong to extension type project.

11. www.company.com Planning Customer / Market requirement Technology Feasibility 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 Business Feasibility Business Plan, Product Requirement Document Internal Capability External Supporting

12. www.company.com Team member and Responsibility BG / BU Head TPM ( Technical Project Manager ) H/W ( Hardware Design ) S/W ( Software Design ) MD ( Mechanical Design ) Power PCB Layout EMC Homologation SafetyLogo Certification Hardware Function Test Compatibility Function Test PE ( Product Engineer ) Manufacturing Process Manufacturing Testing Manufacturing Equipment Manufacturing MQA TPM : Coordinating NPD design / development operation PE : Coordinating NPI operation NPI BPM ( Business Program Manager ) PM ( Product Manager ) PM : Product line operation owner BPM : Coordinating commercial, logistics and fulfillment operation Stability / Reliability Test After Service Material Procurement VQA

13. www.company.com EVT NPD MVTMass Production Activities Timing Planning End of Life management Kick off Concept Design NPD – TPM Technical Project Manager Manufacturing Engineering Fulfillment – BPM Business Program Manager NPI PM : Product Manager DVT NPI – PE Product Engineer Activities, Ownership in Product Life Cycle

14. www.company.com Project Job Handover EVT Design team support MVT Mass production NPD, Design team  PE team NPI, PE team  MT team DVT PE, put NPD Data  NPI TPM  PE PE PE Head as gating approval PE start to take over project PE take over project, design issue support by RD PE, MT team put data into NPI operation PE  MT (ME,TE) MT (ME,TE) MT Head as gating approver PD take over responsibility MT team early manufacturing involvement PE team early involvement as NPD job definition Gating TPM coordinating NPD operation MT coordinating NPI operation

15. www.company.com Project Plan Working Concept Project Plan Specification Cost Delivery BG NPD control flow SOM EVT / DVT / MVT Development Design Verification & Validation Regulation & Certification NPI operation Product DQA Test Guideline SOM ( DQA ) MM Chapter

16. www.company.com Project Plan / NPI Operation Plan Put document On PDM project Folder Project Task Assignment and Control Task assignment No output document task assign by Action Tracking flow in PDM Document Collection Output document in PDM, assign by DCN document box setup Put result on Action Tracking Column Bug tracking operation Assignment in phase beginning !! Operation, attachment, input !! Assign task at phase beginning, Forward & Control by PDM PDM : Product Data Management DCN : Document Change Notice

17. www.company.com Project Charter Project Owner be assigned for the Project NPD/NPI management PDM Project Life control request Kick off meeting, Project brief Project phase plan be forwarded by PDM Project Owner prepare Project plan and be approved by BG/BU Head Project operation Project Life Control Material BOM Bug tracking Project folder PDM database structure for project operation NPD Folder NPI Folder Project Life Control is the mother database to record project life information and as a flag to control project related database creation.

18. www.company.com 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

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

20. www.company.com 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 - Regulatory certification preliminary test EVT Major Activities

21. www.company.com 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 - Parts supply risk management, Procurement of long lead time parts

22. www.company.com 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 MVT ( 4M : Man, Material, Machine, Method )

23. www.company.com Main Flow of Product 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 Test ( DFT ) Design for Availability ( DFA ) Mass Production Manufacturing Quality Assurance ( MQA ) Design for Serviceability ( DFS ) Concurrent Engineering !!

24. www.company.com Design Activity Flow Design Review Design Check List Simulation Specification Regulation Requirement EMC Safety Thermal Design Check List DFM DFT DFA DFS EMC Safety Thermal Design Guideline Approved

25. www.company.com Design Qualification Assurance (DQA) Test Plan Specification Design Qualification Testing (DQA) Bug Alerting and Tracking Design Exit Gating Test Report Product DQA Test Guideline SOM

26. www.company.com 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 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

27. www.company.com 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 ) Verification, Validation Test

28. www.company.com NPI ( New Product Introduction ) Plan and kick-off – Quality / Cost / Delivery / service MFG Process, test development, DFM/DFT Early involvement Material purchasing / Cost / Supplier management, DFA / VQA Material evaluation / Second source alternative Customer service, DFS NPI operation coordination, Design input, Quality requirement Logistic management and Sample build Project Charter SFIS (Shop Floor Information System), Bug tracking system Engineering change management (ECN/ECR/ECR-Design) TPD document creation and management Phase gating Next phase MFG Quality control / Customer Quality Criteria Fail Pass

29. www.company.com MFG Process, Equipment and DFM MFG Testing And DFT Material control, DFA Sample Build After service And DFS MFG Quality Control Coordinator, Get design output data Input Material preparation DFA VQA PE / MDMP/VQA/CE ME / EQ TE PC/MC/HW/PD CS MQA - Parts creation - BOM creation - H/W, S/W, Test code, Mechanical data input - Quality requirement - Coordination - BOM cost - Risk parts management - Material purchasing -Supplier and AVL, AML - Material evaluation AMPL - MFG booking - MFG Scheduling - Material control and keeping - Training and certification - Sample build - MFG Process development - Equipment setup and program - MFG MOI - Stencil - MFG Fixture, - Jig, Carrier - AOI program - ICT fixture and program - FCT fixture and program - Test MOI - WW service site planning - FRU parts MFG and delivery - Test fixture preparation - Repair engineer training Sample Build SFIS Failure collection and Bug Tracking Phase Gating Review Pass Next Phase Yes No NPI Operation Plan Control by PDM Project charter and Kick off NPI Operation Flow - Quality Plan - CSA test - Customer quality requirement - Quality control - Lesson learn collection

30. www.company.com DFM ( Design For Manufacturing ) Quality, Cost Requirement UXX and Supplier Process Requirement Easy Fabrication, Assembly Design Review ( Design Rule,Check List,Lesson Learn ) Early InvolvementBug Alerting and Tracking Shortest Cycle Time, Zero Failure Rate Cost Effective, Time To Volume Requirement Process Target Special Fixture or Tooling Preparing Process Development, MOI, Equipment purchasing Enough Design Margin and Tolerance

31. www.company.com DFT ( Design For Test ) 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 Requirement Process Target Test Program, MOI, Fixture or Tooling Preparing Test Coverage and Backup Solution

32. www.company.com Coverage of Testing AOI ( Automation Optical Inspection ) Planar PTH Process ICT ( In Circuit Test ) test Planar SMT Process The other test solution Backup plan and Solution Parts within Test Coverage FCT ( Functional Test ) test Parts out of Test Coverage DFT Check List Or Design Guideline Lesson Learn DFT Check List / Design Guideline RD Design cycle Start

33. www.company.com SFIS Control for PCBA SAP PDM SFIS W/O BOM ECN PM SN Range Input SN Label Printing SMT AOI Test Result Send to SFIS DB AOIASM SN Barcode Scan Pass/Fail ICT ICT Test result send to SFIS DB FCT FCT Test result send to SFIS DB Check MAC Packing SN/Carton/Pallet No mapping Carton/Pallet Label Printing FQC Record Sampling SN SHIPPING SN/Delivery No mapping Check Model/Qty SFIS ( Shop Floor Information System )

34. www.company.com AVL / AML, Core Supplier Vendor Regular Vendor Qualified Vendor Approved Vendor List (AVL) AgentManufacturer Qualified Manufacturer Approved Mfg’r Vendor (AML) Core Supplier Regular Manufacturer Purchasing focus Partner, MP team periodic provide list Parts selection focus, Have it in SAP system, VQA Maintenance BOM operation focus

35. www.company.com AML List Maintenance ENPD Parts Creation AML database query VQA – Vendor Survey AML Database New MFGer Yes AML / AVL Approval AML Database Start END ENPD Parts Creation No MP agree Yes No Not new parts trigging New Vendor Survey

36. www.company.com Initial CE Approval Start Project Approval Customer Assignment Review Document DQA Test Batch Test Matrix Build Test CE test 3 rd party Lab. Test For the Project only AMPL Database For the Project only Obsolete Phase Out Partial Approval for Grouping parts AMPL : Approved Manufacturer Parts List Material Approval Status and AMPL

37. www.company.com Sample Build ( EVT – MVT ) Material Preparation ( MP,BD,RD,PE ) Material Control ( MC,WH ) Sample Build ( PD ) MFG Scheduling ( PC ) MFG Engineering (MT,PE,RD) MFG Quality Control ( MQA ) MFG Booking ( BD  PC ) Sample UXX internal delivery Start Material Ready Status Review No Yes Re-Schedule

38. www.company.com Development Operation Flow Specification requirement Design Design Output Review Sample build Sample Qualification Test Test Report Design phase gating Bug tracking Sample debug and solution Start Next Phase Action Tracking Periodic Design Review ECN / ECR / ECR – Design

39. www.company.com Severity level of Bug

40. www.company.com Solution Factor

41. www.company.com NPD Phase Operation Design SOW of Phase Operation Plan of Project Plan KPI of Phase DFM/T/A/S Early Manufacturing Involvement Design Quality Assurance (DQA) Task - ( NPD project folder attachment ) Task - ( Action ) TPM Assign Phase Task at phase beginning, Forward & Control by PDM Operation & AttachmentEngineer follow assignment Phase Gating Review to Exit BUGTRACKINGBUGTRACKING PROJECTFOLDERPROJECTFOLDER ACTIONTRACKINGACTIONTRACKING ECR-Design Plan result (Project Folder Data Attachment, Action Tracking) Bug / Deviation ( Bug Tracking ) Ending Beginning Operation ECN / ECR

42. www.company.com ODM Project Operation Gating

43. www.company.com ODM Project Phase Gating EVT gating reviewer gating approver DVT MVT gating reviewer gating reviewer Mass Production gating approver gating approver Pass reject NPD : DQD, QE NPI : ME,TE,MQA NPD: DQD NPD : DQD, QE NPI : ME,TE,PD,MQA RD Head PE Head MT Head Kick off Pass reject Pass

44. Thank you