S3 Stage 3 Flashcards
Design & Development (49 cards)
S3 Stage 3 – Design & Development
In the Design & Development stage, detailed design, development, and system/process integration are completed using best-cost components and processes.
S3.PM Project Manager – Benchmarks
S3.PM.01 Generate Detailed Cost Estimates
S3.PM.02 Update Project Schedule
S3.PM.03 Update Project Metrics
S3.PM.04 Propose Design Reviews to Engineering Steering Committee (MANDATORY)
S3.PM.04.1 NBU CHECK - Conduct Internal and External Design Review if Necessary
S3.PM.04.2 Conduct Reviews of Lean Design and Manufacturability
S3.PM.05 NBU CHECK - Conduct Product Safety Review with Safety Committee (MANDATORY)
S3.PM.06 Update Risk Analysis & Mitigation Plan
S3.PM.07 Manage Regulatory Submittals
Generate Detailed Cost Estimates
S3.PM.01
During this stage, the project team completes their detailed cost estimates.
Update Project Schedule
S3.PM.02
The project schedule is continually updated to show completion of tasks as well as changes or issues with the schedule.
Update Project Metrics
S3.PM.03
As Product Design progresses, the Project Metrics can be updated with more certainty.
Propose Design Reviews to Engineering Steering Committee (MANDATORY)
S3.PM.04
to determine what support is needed from resources outside the developing organization. These could be an individual consultant, supplier, customer, university, etc.
a WBS item so it can be scheduled and budgeted
Engineering Steering Committee – S3.PM.04
- No formal review meeting is required
- An internal review meeting will be conducted with members of the design review group approved by the business unit Engineering VP.
- A limited external review meeting shall be conducted with selected internal members and an outside consultant approved by the business unit Engineering VP and Engineering Steering Committee.
- An extensive external review meeting with multiple external experts in relative fields shall be conducted with selected internal members and an outside consultant approved by the business unit Engineering VP and Engineering Steering Committee.
Design Review checkmarks
- Identification of ultimate customer and user
- User’s needs and expectations for the product
- Functions to be performed by the product
- Design constraints, e.g., size, weight, power requirements
- Pertinent federal, state, local and industry standards concerning safety, reliability, environmental effects, quality, etc.
- Total product cost objective (including installation, maintenance, etc.)
- Conditions of use and possible misuse, e.g., safety, reliability, environmental requirements
- Pertinent information and documentation associated with the total life cycle (design, manufacture, packaging, transportation, installation, use and maintenance, and final disposal) of earlier models of the product under design or of similar products
- Pertinent legislation (enacting and pending) which places constraints on the product design - safety, reliability, environmental requirements
- Pertinent litigation involving personal injury, property damage and environmental damage which could place constraints on the product design
- Schedule requirements
- Design alternatives
- Critical parts to be used
- Identification of high-risk areas (including possibility of any product liability, safety and environmental problems). Include a plan for mitigating all risks identified including Poka Yoke procedures planned for safety critical devices and processes (for example protectors and connections).
- Make-or-buy considerations
- Test and inspection considerations
- Establishing relative rank of importance of all the requirements of the product design
- Possible inventions as well as potential process inventions
- Product specification including electrical, mechanical, and manufacturing
- Rotor dynamics
- Stress analysis (Electrical/Thermal, Mechanical, Chemical)
- Quality and warranty
- Critical Characteristics (customer requirements and company specific requirements)
- Manufacturing process design and development requirements: existing, changes, improvements, setups, Poka Yokes, in process controls/final inspection methods (gauges, visual, automated), etc.)
- Manufacturing process design parameters (process flow, geometry, limitations, orientation, location, etc.
- Analysis/Studies (mold flow, porosity, process capability, etc.)
- Machine design (new, replacement, redesign/modifications, special tooling/fixtures, etc.)
- Maintenance Requirements (for new equipment, consider changes to existing equipment due to forecast changes)
- Manufacturing expert analysis (internal and/or consultant)
- Manufacturing equipment/process designed to customer specifications
- Software design (new/enhancements) typically used to integrate automated inspection, bar coding, part traceability, data collection systems, etc. (consider maintenance agreements)
- Cost estimates
- Schedule status and review
Conduct Internal and External Design Review if Necessary
S3.PM.04.1 NBU CHECK
- Design for Functional Performance
- Design for Reliability
- Design for Manufacturability
- Design for Sourcing
- Design for Environmental Compliance
Functional Performance – S3.PM.04.1 NBU CHECK
achieving customer requirements in the short term (without considering wear-out failure modes). Typically, the key product performance metrics must be achieved over a range of temperature, voltage, humidity, vibration, electromagnetic compatibility, and other operating conditions specific to each product.
Reliability – S3.PM.04.1 NBU CHECK
achieving the product design life for the specified use environment, and achieving the field failure rate goal during both the warranty period and the product design life. Reliability is extremely important as our reputation depends on it.
Manufacturability – S3.PM.04.1 NBU CHECK
achieving high process capability and statistical control in the assembly plants while minimizing manufacturing costs.
Sourcing – S3.PM.04.1 NBU CHECK
achieving consistent high-quality components and assemblies from suppliers at competitive costs, which requires complete specifications and controls at the suppliers. Failure to achieve Design for Manufacturability and Design for Sourcing jeopardizes reliability because nonconforming components and assemblies, if undetected, can cause field failures. In recent years, Design for Manufacturability and Design for Sourcing have been identified as the largest technical challenges in NPD. Technical management of complex supply chain is extremely important to consistently receive high quality components and assemblies, and requires complete specifications, supplier capability validation and supplier control plans.
Environmental Compliance –S3.PM.04.1 NBU CHECK
achieving global environmental legislation compliance for the new product release, and all subsequent production, and includes elimination of “banned” and “at risk” materials, justification for using restricted materials, conformance with compliance documents and incorporation of desired “eco-footprint” into product designs.
Conduct Reviews of Lean Design and Manufacturability
S3.PM.04.2
See activity S3.ENG.01.3 Review Design for Manufacturing and Assembly.
Conduct Product Safety Review with Safety Committee (MANDATORY)
S3.PM.05 NBU CHECK
A formal product safety review must be conducted on all new product designs and major redesigns.
project manager needs to contact the NMC Product Safety Officer when it is time to set up a product safety review.
Update Risk Analysis & Mitigation Plan
S3.PM.06
Review and update the Risk Assessment & Mitigation Plan presented at Gate 1.
Manage Regulatory Submittals
S3.PM.07
Depending on the customer, product, or end use requirement, the project team may want to obtain component recognition or certification of a product with various safety testing agencies with published standards (codes) for construction, materials, insulation systems, thermal overload protection, and operating temperature limits of electro-mechanical devices
S3.MAR Marketing / Product Management
S3.MAR.01 Update Business Plan
S3.MAR.02 Update Sales Forecast
Update Business Plan
S3.MAR.01
The Business Plan from Gate 2 is updated in preparation for the A.R.
Cost information should be much better understood toward the end of the design stage.
Update Sales Forecast
S3.MAR.02
The Sales forecast must be current to drive financial calculations.
S3.ENG Engineering
S3.ENG.01 Create and Develop Designs Using Best Practices
S3.ENG.01.1 Finite Element Analysis (FEA)
S3.ENG.01.2 Computational Fluid Dynamics (CFD)
S3.ENG.01.3 Review Design for Manufacturing & Assembly (DFMA)
S3.ENG.01.4 Complete Design Failure Mode & Effects Analysis (DFMEA)
S3.ENG.01.5 Freeze the Design
S3.ENG.01.6 Prepare Production Drawings, Engineering Specs, Material Specs and BOMs
S3.ENG.02 Review Design vs. Competition
S3.ENG.03 Finalize Prototypes and Test Plan
S3.ENG.03.1 Build & Test Prototypes
S3.ENG.03.2 Complete all Performance Fit and Function Tests
S3.ENG.03.3 Perform Sound/Vibration analysis
S3.ENG.03.4 Update & Freeze Reliability & Qualification Requirements
S3.ENG.03.5 Perform Reliability Tests
S3.ENG.04 Coordinate Customer Tests & Obtain Prototype Part Approval
S3.ENG.05 Obtain Standards Approval
S3.ENG.06 Submit Patents & Plan Product Patent Marking
Create and Develop Designs Using Best Practices
S3.ENG.01
Detailed product designs may include layout, solid models, 2D and 3D drawings, and simple bills of material.
Finite Element Analysis (FEA)
S3.ENG.01.1
Finite Element Analysis (FEA) is a mechanical and electromagnetic analytical technique used to predict stress in part configurations.
