Flawless product launches
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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

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MFG/PROMidwest User Group

Fall Conference2006

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.

  • This presentation will discuss the technology available to execute product launches, not just track how far behind you are.

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


Product Launch Challenges

  • 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


  • We All Know Poor Launches Are Costly

  • Or You Wouldn’t Be Here

  • 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

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 ?

  • 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 is my risk?

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

  • 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

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 ….

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


  • 2.1 Design FMEA

  • 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 …”Project Management vs. Project Execution

Subtitle: The Tale of the Dead Docs


Project Management vs Project Execution

  • 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 !


Documents and Attachments Versus 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)


Lean Product Launch


What you think it is

  • What it actually is

What it should be

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


Example Reporting Nightmare

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

Opportunity

Gap


Flawless Launch – IQS Bridge the Gap

  • 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

Customer Master

Supplier Master

Item Master

Employee Master

Change Management

Incoming Receipts


NEW PROGRAM APQP


  • APQP TASK LISTS

  • Customer

  • Internal

  • Supplier


EXAMPLE CHECKLIST


Engineering Portal


Management of Characteristics


DESIGN FMEA


PROCESS FLOW


PROCESS FMEA


CONTROL PLAN


Engineering Change Management

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


Engineering Changes – 3 Steps


Employee Suggestion Life Cycle

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 – ECR, ECN, ECO


Robust Change Management Options

  • Single Change Request Against Multiple Products

  • Single Product to Multiple Change Requests

  • Single Product that Affects Multiple Products


Product Change Life Cycle

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

  • 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


  • What Current Process is

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


Summary 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?

  • 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

Flawless Product Launches

IQS, Inc.

19706 Center Ridge Road

Cleveland, Ohio 44116

440-333-1344

www.iqs.com


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