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S2 Stage 2 Flashcards

Project Planning & Concept Development (74 cards)

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1
Q

Stage 2 Project Planning and Development

A

the cross functional team collaborates to substantiate the market (customer) need and product value based on the functional requirements in order to complete a concept design and demonstrate a proof-of-concept.

The team is to assess and justify the required resource and capital investment and develop a project plan to meet the project objectives with reasonable certainty and within required timelines.

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2
Q

Initiate the Project & Review Program Goals and Objectives

A

S2.PM.01

During the Planning Stage, the project team defines the specific goals and objectives of the project.

Two aspects to this determination are defining the product and project scope.

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3
Q

Create Project Plan and Schedule

A

S2.PM.02

defines; activities, duration, dependencies, and milestones of the project

During the early efforts of the Planning Stage, the project team develops a project Work Breakdown Structure (WBS).

A Gantt chart should be prepared with team members using MS Project or an equivalent tool.

benefit of CPA is that it helps to identify the minimum length of time needed to complete a project.

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4
Q

Work Breakdown Structure

A

WBS

A WBS is a deliverable grouping of project activities that organize and define the scope of the project (work not in the WBS is outside the scope of the project)

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5
Q

Critical Path Analysis

A

CPA

formally identifies those tasks which must be completed on time for the whole project to be completed on time.

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6
Q

Create Project Budget & Expense Forecast

A

S2.PM.03

project team fully defines estimated expenses

These expenses could include, but are not limited to; staff hours, laboratory, computer support, travel, prototypes, and miscellaneous expenses. These estimated expenses become the budget for the Project team.

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7
Q

Perform Risk Analysis

A

S2.PM.04

Risk management includes the processes concerned with identifying, analyzing, and responding to project risk.

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8
Q

Risk Identification

A

determining which risks are likely to affect the project and documenting the characteristics of each

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9
Q

Risk Quantification

A

evaluating the risks and risk interactions to assess the range of possible project outcomes

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10
Q

Risk Response Development

A

defining enhancement steps for opportunities and responses to threats

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11
Q

Risk Response Control

A

responding to changes in risk over the course of the project.
These risks can be product or project related

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12
Q

Organize Project Team

A

S2.PM.05

Division Management appoints a project team

A cross-functional team generally consists of representatives from Engineering, Marketing, and Manufacturing. Depending on the size and complexity of the project, other team members may be included from organizations such as Application Engineering, the Customer, Purchasing, Quality Assurance, Plant Engineering, Plant Production, Accounting, or Vendors.

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13
Q

Hold Project Kick off & Review Meetings

A

S2.PM.06

the project manager or team leader calls a Project Kick-off Meeting to define organizational and technical interfaces between different groups that input into the design process.

The purpose of this meeting is to agree on the technical, cost, and schedule goals of the project and begin forming the specific plans for project execution.

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14
Q

Conduct a Lean/Complexity Review

A

S2.PM.07

Conduct a Lean review meeting to evaluate the complexity impact of the product or process to the business.

Use the Complexity Indicator Worksheet to help rank the complexity of the project.

Objective: understand, evaluate and approve the complexity impact to other division products, operations organizations and supply chain.

Func Areas Needed: Product Management (Platform Leader), Engineering, Procurement and Operations

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15
Q

Review History / Lessons Learned / Team Experience

A

S2.PM.08

The project team should review historical customer concerns and wants in order to assess the potential for recurrence during the design, manufacture, installation and use of the product

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16
Q

Develop Preliminary List of Special Product & Process Characteristics

A

S2.PM.09

Special product and process characteristics are identified by the customer in addition to those selected by the organization through knowledge of the product and process

tracked in the APQP process

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17
Q

Special Product Characteristics

A
  • Product assumptions based on the analysis of customer needs and expectations
  • Identification of reliability goals and requirements
  • Identification of special process characteristics from the anticipated manufacturing processes
  • Similar part FMEAs
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18
Q

Special Product Characteristics FLOW

A

hese Critical to Quality (CTQ) requirements need to flow down and be documented in the engineering drawings, DFMEA, Prototype Control Plan, Process Flow Chart, Process Failure Mode Effects Analysis (PFMEA), Production Control Plan and Plant Work Instructions.

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19
Q

Key Characteristics Classification LINKED

A

Voice of Customer -> Identification of Critical Characteristics -> Drawings -> Design FMEA -> Prototype Control Plan -> Process Flow Chart -> Process FMEA -> Production Control Plan -> Operator Instructions

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20
Q

Create Business Plan & Assess Strategic Fit

A

S2.MAR.01

The business plan and marketing strategy will set the framework for the project plan.

may place constraints (e.g., timing, cost, investment, product positioning, and research and development resources

becomes the financial success criteria that will later be used in Post Launch Reviews.

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21
Q

Update Product Specification

A

S2.MAR.02

Update the product specification

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22
Q

Conduct Competitive Product/Process Benchmarking

A

S2.MAR.03

Analyze real and potential competitive products that exist and benchmarked against our own current product offering if applicable

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23
Q

Perform Branding Recommendation

A

S2.MAR.04

Discussion of how our product will be branded and taken to market

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24
Q

Identify a Product Introduction & Obsolescence Plan

A

S2.MAR.05

Begin to plan how this product will be introduced and if it replaces an existing product, plan how that product may be phased out.

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25
Identify Customer Contract Requirements
S2.MAR.06 VOC At this point, identify what customer(s) are going to want in contracts. Supply provisions, quality requirements as well as terms and conditions are examples of what is to be analyzed.
26
Review Product Specifications & Develop Design Goals
S2.ENG.01 VOC Requirements from the Product Specification and Market Studies are analyzed and an outline design specification developed.
27
Develop Detailed Design Specification
S2.ENG.01.1 * Hardware/Software specifications * Any major innovations that must occur to enable this product * Prioritized system/process requirements traced from features description – scalable options identified * Manufacturing & Operations requirements * Supply chain requirements * Performance and Quality requirements. This includes Critical to Quality (CTQ) flow down characteristics and tolerances * Environmental regulations product may be required to meet. (RoHS, REACH, etc.) * Interface requirements (e.g. other products, systems/processes) * Standards * Aftermarket Strategy
28
Develop an Initial Performance Test Plan
S2.ENG.02 Project Schedule development project teams develop a test plan to include all product and customer testing required prior to project completion
29
Product Test Plan
* High risk elements * Customer performance requirements * Customer engineering standards * Customer reliability standards * Customer quality requirements * Application testing at NMC Motor Technology Center * Customer facility application/laboratory testing * Industry product requirements * Testing Agency approval specifications * U.L. standards compliance verification * Material evaluations * Unproven component design evaluations * Prototype validation * Supplier and Vendor part evaluations * Environmental requirements * Unproven or new process testing * Validation of NMC Test Procedures * Validation of NMC Standard Engineering Instructions for Manufacturing (SEIMs) * Validation of NMC Material Specifications * CAE requirements (i.e., FEA, CFD, Mold Flow, Tolerance Analysis, etc.) * Specification of third party testing.
30
Create Plan for Lean Standards Documentation
S2.ENG.03 project team develops a plan for conformance to Engineering and Product Standards for the Market and customer(s) served by the product. If there are no applicable lean standards pertinent to the product, a plan is put in place to establish a new lean standard The lean standard documentation is a Gate 4 deliverable
31
Establish a Reliability Test Plan
S2.ENG.04 Product testing may include product or customer life testing that may extend beyond the development of the product.
32
Establish a Product Safety Plan
S2.ENG.05 Assess and identify any potential safety issues with proposed designs and begin to mitigate these so they do not become surprises at the Stage 3 Safety Review
33
Review Potential Patent Infringement
S2.ENG.06 The project manager or team leader consults with NMC’s Intellectual Property Department and provides them with sufficient information to allow for a search of existing similar product designs to ensure the product is not in violation of a current patent. The project team conducts a prior art search
34
Review Initial Manufacturing Processes
S2.MFG.01 The product concept is reviewed with Business Unit Manufacturing to assess the need for any process development (could be outsourced to find supply more readily).
35
Analyze Initial Manufacturing Facility Recommendations & Options
S2.MFG.02 Along with the Process Review, the options for production location(s) and available capacity are assessed
36
Identify Design for Manufacturing & Assembly requirements
S2.MFG.03 Based upon the product complexity and proposed manufacturing approach for the product concept, the project team may need to use one of the Design For Manufacturing and Assembly (DFMA) techniques discussed in Stage 3
37
Preliminary Process Flow Chart
S2.MFG.04 The anticipated manufacturing processes should be described using a process flow chart developed from the preliminary bill of material and product/process assumptions
38
Establish an Initial Supply Chain Plan
S2.PRO.01
39
Involve Suppliers and Partners as appropriate
S2.PRO.02 As early as possible, the project team begins involving potential suppliers, partners, and consultants. Notify suppliers of Full Material Disclosure requirement at the First Parts Approval process Declaration of conformance to REACH and RoHS regulations (When the supplier cannot fulfill the complete order).
40
Communicate Project Specific Quality Requirements
S2.PRO.03 Ensure the suppliers understand and are committed to the specific quality requirements of this project.
41
Identify New Diagnostic Tools to Support Warranty Analysis
S2.SER.01 Understand customer service and warranty expectations and what if any changes to our existing infrastructure may be needed to support their expectations
42
S2.QUA Quality - Benchmark
As appropriate for the project a Quality leader, or APQP leader, should be assigned to the project team so that they may oversee and insure the elements of the Quality / APQP process is executed as part of the Project Team NPD process deliverables.
43
Assess Initial Quality Requirements & Reliability Goals
S2.QUA.01 Based on analysis of the product concept and the requirements of the target market and customers, a list of initial quality requirements is prepared to guide the design effort The Quality / APQP leader, should assist the Project Manager in developing the Special Product & Processes Key Characteristics
44
Outline a Quality / Assurance Plan or APQP Process Methodology as Appropriate
S2.QUA.02 The project team outlines an initial Quality Assurance Plan, or establishes an APQP Process checklist
45
Quality / Assurance Plan | APQP Process
includes an estimate of the cost and resources required to assure the quality of the product concept will meet the requirements of the target market and customers. integrated into the Business Plan for Gate 2
46
Estimate the Cost of Quality
S2.QUA.03 Cost of Quality represents the difference between the actual cost of a product or service and what the reduced cost would be if there were no possibility of substandard service, failure of products or defects in their manufacture.
47
Cost of Quality Includes
``` Prevention Costs Appraisal Costs Failure Costs Internal Failure Costs External Failure Costs ```
48
Prevention Costs –
``` The costs of all activities specifically designed to prevent poor quality in products or services. Prevention Costs examples: • New product review • Quality planning • Supplier capability surveys • Process capability evaluations • Quality improvement team meetings • Quality improvement projects • Quality education and training ```
49
Appraisal Costs –
The costs associated with measuring, evaluating or auditing products or services to assure conformance to quality standards and performance requirements. Appraisal Costs examples: • Incoming and source inspection/test of purchased material • In-process and final inspection/test • Product, process or service audits • Calibration of measuring and test equipment • Associated supplies and materials
50
Failure Costs –
The cost resulting from products or services not conforming to requirements or customer/user needs. Failure costs are divided into internal and external failure categories.
51
Internal Failure Costs –
``` Failure costs occurring prior to delivery or shipment of the product, or the furnishing of a service to the customer. Internal Failure Costs examples: • Scrap • Rework • Re-inspection • Re-testing • Material review • Downgrading ```
52
External Failure Costs –
``` Failure costs occurring after delivery or shipment of the product — and during or after furnishing of a service — to the customer. External Failure Costs examples: • Processing customer complaints • Customer returns • Warranty claims • Product recalls ```
53
Business Plan Approval
G2 Gate 2 At this Gate, the Business Plan for the project is approved after assessment of the financial metrics, risk, and return. This authorizes the team to proceed to the Design and Development stage. In addition, the success criteria are established for comparison at Gate 5 and Post Launch
54
G2.PM Project Manager - Reports on
G2.PM.01 Project Plan and Schedule G2.PM.02 Updated Project Attractiveness Scoring G2.PM.03 Risk Assessment G2.PM.04 Lean/Complexity Review G2.PM.05 Preliminary List of Special Product & Process Characteristics
55
Project Plan and Schedule
G2.PM.01 A summary of the Project Plan, schedule, and budget is presented.
56
Updated Project Attractiveness Scoring
G2.PM.02
57
Risk Assessment
G2.PM.03 Present a summary of the risk assessment performed in Stage 2.
58
Lean/Complexity Review
G2.PM.04 Present the outcome of the lean/complexity review.
59
Preliminary List of Special Product & Process Characteristics
G2.PM.05 Document a preliminary list of special product and process characteristics
60
G2.MAR Marketing / Product Management -- Reports on
Add details of the role of Marketing / Product Management function in this Gate.
61
Business Plan
G2.MAR.01 The Business Plan including the forecast, risks, and financial return is presented, and summarizes project financials.
62
Review of Competitive Product/Process Benchmarking
G2.MAR.02 Present an overview of competition to be taken into consideration during the design stage
63
Value Based Pricing Strategy
G2.MAR.03 Assess what opportunities the concept presents for value based pricing.
64
Branding Strategy
G2.MAR.04 Outline how we will take this concept to market and how we will brand it.
65
Product Requirements Specification
G2.MAR.05 Based on the voice of customer analysis and unmet needs of the marketplace, deliver a product requirements specification for the project team to begin the design and development process of a new product that meets our customer/market expectations.
66
Product Requirements, Architecture and Design Goals
G2.ENG.01 Design goals should be developed from the product requirements specification document to ensure the Voice of the Customer is not lost in subsequent design activity.
67
Concept Test Results
G2.ENG.02 If there has been testing done on the concept, particularly compared to competitive products, it will be summarized here to help with the Business Case discussion.
68
G2.MFG Manufacturing
Summarize important results of the initial Manufacturing reviews performed on the concept.
69
Initial Manufacturing Process & Design Requirements
G2.MFG.01 Identify and document any new manufacturing processes that need to be developed or outsourced.
70
Initial Manufacturing Facility Recommendations and Options
G2.MFG.02 Present the initial manufacturing and facility requirements.
71
Preliminary Process Flow Chart
G2.MFG.03 Document preliminary process flow cha
72
G2.PRO Procurement
G2.PRO.01 -- Initial Procurement Plan Summarize the initial Procurement Plan.
73
Initial Quality / Assurance Plan
G2.QUA.01 Summarize any special quality requirements that could affect the success of the project.
74
Quality and Reliability Goals
G2.QUA.02 Summarize any reliability goals that could affect the success of the project.

PM - Nidec (10 decks)

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