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MFG/PRO Midwest User Group Fall Conference 2006. Flawless Product Launches. PRESENTED BY John M. Cachat, IQS Dave Doyle, QAD. The current “state of the art” in most companies include MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

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Flawless product launches

MFG/PROMidwest User Group

Fall Conference2006

Flawless Product Launches

PRESENTED BY

John M. Cachat, IQS

Dave Doyle, QAD


The system must do the work – not just report on it.


Product launch challenges
Product Launch Challenges MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • What Tools We Have - What We Are Missing

  • Identifying Waste In The Process

  • Eliminating Waste In The Process

  • Optimization – QAD And IQS Integration

  • Flawless Product Launch - Keys To Success


  • Products Arrive LATE

    • Competitor Gets Out First – Cell Phones – Lost Of Sales

    • Snow Blowers In June – Who Cares – No Sales

    • Cars Without MP3 Players Or IPod Connectors

  • Is The Challenge Innovation Or Execution ?

  • No One Plans To Be Late

    • They Knew What It Took To Produce The Cell Phones

    • The Plan Showed Snow Blower Delivery For December

    • Design Engineers Have IPods And Are Frustrated Too


Product launch its about execution
Product Launch -- Its About Execution MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

OYAMA, Japan – August 25, 2006| “Toyota may delay the launch of some of its new models, the company’s president said today, as the world’s No. 2 automaker tries to improve its quality process in order to reduce a spate of recalls that is threatening its reputation”

“Watanabe said that the emphasis was on making sure quality procedures were properly carried out, rather than on how much time the process took.”

Toyota’s shares fell 60 yen, or 0.95 percent today.

Product Launch – It’s A Bottom Line Issue


What is flawless launch
What Is Flawless Launch ? MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • It Is About Optimizing Constraints

    • Time

    • Quality

    • Cost

  • Identifying & Resolving Flaws

    • Reduce Variation

    • Eliminate Waste

  • Life Cycle Process

    • Not Departmental

    • Not Documents

Quality

Quality

Time

Cost

Engineering

Cost


What works what is missing

What is my risk? MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Is the Supplier

Performing?

Where is the FMEA?

What is the status

Of my ECN?

Is there a control plan?

WHY is the

Part on hold?

What are the key

Characteristics?

Scheduling

Engineering

Bill of

Material

Labor andMaterial Cost

Document Vault

Shipping

What Works – What is Missing


Automotive product launch
Automotive Product Launch MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • Project Plan

  • 5 Phases

  • 23 Elements

  • 1.0 Plan and Define

  • 2.0 Product Design and Develop

  • 3.0 Process Design and Develop

  • 4.0 Product and Process Validation

  • 5.0 Feedback, Assessment, Corrective Action


Plan and define program
Plan and Define Program MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Project Plan

  • 1.1 Voice of the Customer

  • 1.1.1 Market Research

  • 1.1.2 Historical Warranty and Quality Information

  • 1.1.3 Team Experience

  • 1.2 Business Plan/ Marketing Strategy

  • 1.3 Product/ Process Benchmark Data

  • 1.4 Product/ Process Assumptions

  • 1.5 Product Reliability Studies

  • 1.6 Customer Inputs

  • 1.7 Design Goals

  • 1.8 Reliability and Quality Goals

  • 1.9 Preliminary Bill of Material

  • 1.10 Preliminary Process Flow Chart

  • 1.11 Preliminary Special Characteristics

  • 1.12 Product Assurance Plan

  • 1.13 Management Support

1.1.2 Historical Warranty and Quality Information

14,000 Parts Per Vehicle

x

100 Characteristics

Each

1.11 Preliminary Special Characteristics

The Devil Is in the Details


Its 8 30 monday morning
Its 8:30 Monday Morning …. MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Do you know where your details are?

  • 2.1 Design FMEA

  • 2.2 Design for Manufacturability and Assembly

  • 2.3 Design Verification

  • 2.4 Design Reviews

  • 2.5 Prototype Build - Control Plan

  • 2.6 Engineering Drawings

  • 2.7 Engineering Specifications

  • 2.8 Material Specifications

  • 2.9 Drawing and Specification Changes

  • 2.10 New Equipment, Tooling and Facilities Requirements

  • 2.11 Special Characteristics

  • 2.12 Gages/ Testing Equipment Requirements

  • 2.13 Team Feasibility Commitment


Create and use the detailed information

  • 2.1 Design FMEA MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • 2.2 Design for Mfg & Assembly

  • 2.3 Design Verification

  • 2.4 Design Reviews

  • 2.5 Prototype Build - Control Plan

  • 2.6 Engineering Drawings

  • 2.7 Engineering Specifications

  • 2.8 Material Specifications

  • 2.9 Drawing and Specification Chgs

  • 2.10 New Equipment, Tooling Req

  • 2.11 Special Characteristics

  • 2.12 Gages/ Testing Equipment Req

  • 2.13 Team Feasibility Commitment

Opportunity

Gap

Create and Use the Detailed Information


“But it’s on my project plan …” MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems. Project Management vs. Project Execution

Subtitle: The Tale of the Dead Docs


Project management vs project execution
Project Management vs Project Execution MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • Project Management tells you

    • What, When

  • ProjectExecution

    • Is doing the What

  • Execution Details are often managed with attachments

  • Attachments Become Dead documents that Generate Waste !


Fmea s have the power to manage risk

Documents and Attachments Versus Business Systems MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

FMEA’s Have the Power to Manage Risk

FMEA

CHANGES

FMEA

ACTION ITEMS

CONTROL

PLAN

CHANGES

FMEA

RPN ANALYSIS

  • FEEDBACKTO ENGINEERING

  • Severity

  • - Occurrence

  • Detection

CONTROL PLAN

FMEA


Eliminate waste lean reduce variation six sigma
Eliminate Waste MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems. (Lean)Reduce Variation(Six Sigma)


Lean product launch
Lean Product Launch MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Tremendous amount of non value added waste in the launch process

What you think it is MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • What it actually is

What it should be

Tremendous Amount of Non-Value-Added Waste in the Launch Process


Example Reporting Nightmare MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

This Is A HUGE Waste Of Labor To Create And Update Reports Because There Is Not An Enterprise Systems That Consolidates The Data For Reporting

Even Worse,

Every Department Has There Own Version


Reduce variation eliminate waste
Reduce Variation – Eliminate Waste MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Opportunity

Gap


Flawless launch iqs bridge the gap
Flawless Launch – IQS Bridge the Gap MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • IQS fill the gap

    • Capture Details

    • Coordinate Details

    • Communicate Details

  • Centralized Data Hub

    • One off Details

    • Legacy Systems

  • Visibility

    • Tell me what, and WHY


Qad and iqs working together
QAD and IQS Working Together MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Customer Master

Supplier Master

Item Master

Employee Master

Change Management

Incoming Receipts


NEW PROGRAM APQP MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


  • APQP TASK LISTS MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • Customer

  • Internal

  • Supplier


EXAMPLE CHECKLIST MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Engineering portal
Engineering Portal MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Management of Characteristics MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


DESIGN FMEA MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


PROCESS FLOW MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


PROCESS FMEA MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


CONTROL PLAN MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Engineering Change Management MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

is one of the biggest challenges in the product launch and manufacturing


Engineering changes 3 steps
Engineering Changes – 3 Steps MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Employee suggestion life cycle
Employee Suggestion Life Cycle MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Reject

Revoke

Reroute

PCR Creation

Release

Notices

Route for Approval

Electronic Approvals

comments

NO

YES

Release/Distribute

Convert to PCO


Change management workflows
Change Management Workflows MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Change management ecr ecn eco
Change Management – ECR, ECN, ECO MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Robust change management options
Robust Change Management Options MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • Single Change Request Against Multiple Products

  • Single Product to Multiple Change Requests

  • Single Product that Affects Multiple Products


Product change life cycle
Product Change Life Cycle MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Reject

Revoke

Reroute

PCO Creation

Release

Notices

Route for Approval

Electronic Approvals

comments

NO

YES

Release/Distribute

Planning

Systems

Dates

Implementation


Product change request approvals
Product Change Request Approvals MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

  • Workflow

  • Approved By List

    • Includes Hierarchy And Stop If Not Approved Then Automatically Posted To Change Request When Product ID Is Entered

  • Email Notification Is Available

  • Escalation Available


Identify and eliminate waste in the launch process

  • What Current Process is MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

What it Needs to be

Identify and Eliminate Waste in the Launch Process

Can you identify

your current process?

Use integrated tools to streamline.


Incorporate integrated tools
Incorporate Integrated tools MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.


Summary flawless launches
Summary MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems. Flawless Launches

  • Single Source of Information is Critical

  • Consolidate Stand Alone Tools

  • Use Existing Enterprise Software Data

  • Reduce Variation, Eliminate Waste

  • Solve the Execution Problem


Why iqs and why now
Why MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems. IQS and Why Now?

  • Off the Shelf Integration with QAD

  • Tangible $ Savings Today

  • Extension QAD Investment

  • Document Authoring Solution

  • Competitive Opportunity

    • Faster Time to Market

    • Lower Warranty Costs

    • Early Warning System

    • Lower IT Costs


Q & A MS Project & MS Excel. These tools are personal productivity tools – not enterprise business systems.

Flawless Product Launches

IQS, Inc.

19706 Center Ridge Road

Cleveland, Ohio 44116

440-333-1344

www.iqs.com


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