DEVELOPMENT
MANAGEMENT
PILLAR
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Background
1. High Lead Time
2. High Product Development Cost
Slow
vertical
start up
Low
Poor Jishu
Maintainab
Hozen ability
ility
Why
DM ?
Weak
Re occurrence
Ergonomic&
of design errors
Safety
Difficulty in Low OEE in
Operability new
equipment
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Background
• Less focus on continual improvement for development and
improvement of required of product, technology, processes and
up gradation of equipment.
• Losses like Slow Start-ups, Re-occurrence of Design errors, and
High lead-time low maintainability, low OEE of new equipment
not focused during initial stage of DM.
• Very low focus on Cost review, Design review and time during
DM activity.
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Scope of Development Management
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AIM & Objectives
To achieve vertical start up of new equipment & reduce lead time for new product
development.
Products: To develop products with faster development time and high vitality
Equipment: To develop cost-effective, reliable equipment with vertical start-up; free from
losses. To develop standard equipment which should have reliability, maintainability,
operability & flexibility.
❖To develop PRODUCT shall be : ❖To develop an EQUIPMENT which is :
•Free from manual elements & Losses
•Easy to manufacture.
•Easy to maintain, Operate /Use
•Better reliability.
•Produces defect free component.
•Shortest lead time for
development. •Safe.
•First time OK •Having longer service life .
•At lower cost through VAVE •Minimum downtime for replacement of
spares.
•Minimum Minor Stoppages
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Linkage Between KMI, KPI & KAI
KMI KPI KPI 2 KAI Index
1.1.1) FMEA Revisit against customer
1 .OEE Improvement in PDC
complaint
1.1- OEE of new equipment 2 .OEE Improvement in Machine Shop
1.1.2) No of MP Sheets Utilization
should be Above 90% 3 .OEE Improvement in Paint Shop ( Jhability , Maintainability, Reliability,
4 .OEE Improvement in Assly shop Operability )
5. .OEE Improvement in Plating Shop
1 .Set up Change Reduction in PDC
2 .Set up Change Reduction in Machine Shop
1.2 - Setup change time of new 1.2.1) No. of MP Sheets Utilization (
3 .Set up Change Reduction in Paint Shop
Increase equipment should be single digit Flexibility MPs)
4 .Set up Change Reductionin Assly shop
Production
5. Set up Change Reductionin Plating Shop
1.3.1) Planning Time Reduction ( Gantt
1 .Lead Time Reduction in PDC
Chart Preperation )
1.3.2) Use of ECRS techniques through CFT
2 .Lead Time Reduction in Machine Shop
approach
1.3 - Lead time Reduction
3 .Lead Time Reduction in Paint Shop 1.3.2) Use of Series to Parallel Planning
4 .Lead Time Reduction Assly shop 1.3.3) External to Inhouse Development
5. Lead Time Reduction Plating Shop 1.3.4) Installation Time Reduction
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Linkage Between KMI, KPI & KAI
KMI KPI KPI 2 KAI Index
2.1.1 ) Adopting DR1 to DR3 ( Drawing
1 .First time right parts developed in PDC Study, Feasibility Study, Poka -Yoke
Possibility Study)
2.1.2) Covering all Q Components in New
2 .First time right parts developed in Machine
Product IPO, Implimentation of reliabiltiy
Shop
Zero Customer MPs in New equipment dev.
2.1 - First time right 2.1.3) Use of advance techinques for defect
Complaint 3 .First time right parts developed in Paint
analysis and prevention (CTQ PQS Study ,
Shop
PRBFM Study etc)
4 .First time right parts developed in Assembly
2.1.4 ) Use of Quality Maintanability MPs
Shop
5 .First time right parts developed in Plating
1 Reduce initial cost equipment by 10%
1.5.1 New Fixture Development Cost
developed in PDC (Dies )
Reduction
2 Reduce initial cost equipment by 10%
1.5.2 Toolings Cost Reduction through
developed in Machine shop
Development 3.1 Reduce initial Cost of 3 Reduce initial cost equipment by 10%
Cost Reduction Equipment by 10% developed in Paint shop
4 Reduce initial cost equipment by 10% 1.5.3- Standardization of Spares to reduce
developed in Assembly Shop Spare / Inventory cost
5 Reduce initial cost equipment by 10%
developed in Plating Shop
1 Accident Free Equipment Developed In PDC
2 Accident Free Equipment Developed In
Machine Shop
3 Accident Free Equipment Developed In Paint
4.1 Accident free Equipment, 1.6.1 - number of MP Sheets with respect
Zero Accident Shop
fixture ,Dies of safety
4 Accident Free Equipment Developed In
Assembly Shop
5 Accident Free Equipment Developed In
Plating Shop
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KPI Target
KMI KPI-1 UOM Better BM 2008 AEL Target
1.1- OEE of new
equipment should be %
Above 90%
1.2 - Setup change time
of new equipment Min/Mont
should be single digit h
Increase
Production
1.3 - Lead time
Reduction Weeks
No.OF
Customer
2.1 - First time right Sir/Occ.
Complaint Zero Avg.
4.1 Accident free Nos.of
Zero Accident Equipment, fixture ,Dies Projects
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Master Plan
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Pillar Support activity Pillar Support activity
KK Improve OEE of machines Improvement Kaizens for design
KK change and equipment
JH JH Ability for m/c
New technology improvement and
Improvement in CLITA , MP sheets
process improvement in maintainability JH
PM
Improvement in equipment and
PM maintainability Kaizens
Area of improvement in design , Q
DM component , 4M improvement inputs D
QM with modified changes M
QM 4 M analysis and FMEA
OTPM MP sheet s from offices
Optimize office improvement
OTPM Equipment safety MP sheets
SHE
SHE Improve machine safety
Training session to enhance new
Skill enhancement of People for E&T technology skill
E&T automation
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MP System
MP Sheet Generation - Methodology
Responsibility
Activity Identification of Losses KK
JH
Kaizen Against Losses PM
QM
New Product Scrutinizing of worthy SHE
Requirement kaizen w.r.t. family of machines OTPM
Identification of MP worthy kaizen (kaizen
related to design change of equipment &
mold fixture
MP sheet generation
/ Updation DM Team
Members
Classification of date according to
Inputs from latest
MP attributes
Methodology Types of equipment / dies
Updation of Equipment standard,
guideline & checklists
MP Design
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MP System
MP Information Management
MP Themes by Different Pillar
JH KK PM QM SHE MH
For For For For For For
For Ease of Operability Maintability Reliability Safety Material
CLITA Reliability and Handling
Energy Saving
MP Sheet Compilation
Incorporation of MP Learning in Standard Manual
MP Learning Application to New Machine & Tool
Provide Standard MP Learning Manual to Supplier
while finalizing Technical Scope.
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MP Information Sheet
Date of Completion:
Completed by:
Improvement Theme:
Problem: Registration Code:
Name of Facility:
Control No.
Cause: *Target of improvement Previous:
1. Reliability
2. Maintainability
3. Autonomous
Maintainability
Before Improvement After Improvement
Effect: (Cost estimtion: Possible or not possible) Standardisation for maintenance work:
Change:
Other:
Total Amount: Effective amount reported: Horizontal Deployment:
A. Necessity B. Classification C. Cause D. Target E. Standardisation
1. Feed-Back must be 1. Change mechanism and 1. Less process capability 1. Improvement in reliability 1. Engg Std. Document
construction/Structure
2. Necessary, if possible 2. Change in operation (Func.) 2. Design failure 2. Improvement in maintainability 2. Manufacturing Drawing
3 3. Change in control circuit 3. Manufacturing defect 3. Improvement in autonomous 3. Spec. Document
maintainability
4 4. Change Raw Material 4. Spec. defect 4. Improvement in operability 4
5 5. Change Parts 5. Assembling defect 5. Improvement in Energy Saving 5
6 6. Others 6 6. Improvement in safety 6
Opinion
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New Product Development
Objective :
To develop new product free from losses, defects, unnecessary cost
and should start with vertical start up (rapid stabilization) for mass
production.
METHODOLOGY :
OBJECTIVES METHODOLOGY
a. Adequate Input from
Customer
First Time
b. Application study
Right
c. Relate with past trouble of customer complain of
existing product
a. Reduction of failure by new technology and
Development Lead Time
validation Simulation
a. By Supporting Automation
Ramp up Production b. By doing process optimization
Activity c. Verification & validation of component at supplier
end for first time right.
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Development Management System Development Management System
S.No Activity S.No Activity
1 Get Customer Requirement 19 Design Review
2 Prepare Master Schedule 20 Facility Development
3 Form CFT for Development 21 Tool Design and Development
4 Prepare Design and Development Plant 22 Make Samples
5 Prepare Capacity Planning 23 SIR Reports Checks
6 Decision Making for Inhouse / External / Modification 24 Run At Rate Audit for Negative Issues / Process Improvements
7 Prepare Capex 25 Inspection Aggreement Sign offs
8 Prepare BOCP arrangement Plan 26 Submit Samples to Customers for SIR Approvals
9 Prepare Material Movement Plan 27 Prepare Packing Standards
10 Releasing Drawing and Item Code Lists 28 Update FMEA
11 Prepare Process Flows 29 Prepare QA Matrix
12 Prepare Stagewise Inspection Checksheets 30 Update 4M1T Check sheet
13 Prepare PFMEA 31 Update PM / JH Checksheets
14 Prepare 4M1T Control Plan 32 Operator Training
15 Prepare Inspection and Test Equipment Plan 33 Over All Process Tryout
16 Prepare List of new Equipment Tooling and Facilities 34 Submit Samples to Customers for Change Management
17 Prepare Tool Progress Report 35 Start of Production
18 Prepare Facility Development Schedule 36 Process Capability Study
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New Product Process Development
APPROACH FOR NPD (DR1- DR7):
INPUT STAGE OUTPUT
Part Drawing
Preferred Vendor list Selected vendor & CFT
DR1 –
PIS / NCR / QSR status of vendor Vendor selection PRBFM , CTQ Sign Off
PRBFM Inputs
Aesthetic are (A,B,C) DR2 –
Process flow , QA Matrix, IPO Docs.
Check sheet Design, PQS Drawing study
Final / in process inspection Sheets
PRBFM check sheet Time line chart for machines
Present process capability data ,Tooling's, Gauges, Testing equips
DR3 –
Guidelines – Process , Gauges, Inspection Process Planning Poka Yoke identification for
Testing error proofing
Guideline for part handling , Fixture Design
PRBFM Check sheet , Process Standards Improvement list , Updated 4M1T
DR4 –
KHI Guidelines, Packaging Standard SIR (Vendor & Our Company)
Trial Production
List of preferred tool manufacturing vendors
Guidelines for floor plan layout Improvement list
DR5 Stage – wise JH/PM Sheets
Final tooling Pre - Pilot
Validation standard
Improvement list: Pilot
Tool tryout improvement list closer DR6 –
Pilot Final documentation
Run at rate check sheet DWM check sheet
DR7 - SOP Inspection Agreement
Closer of all improvement issues
Q Alerts to plant
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New Product Development
Component Targets:
UOM Bench Mark Part Target
Models
P OEE %
Customer Complaints PPM
QSR issues Nos.
EFR (No. of
Nos.
Phenomenon)
Q
In-house rejection PPM
First time right
No of
(Sample submission &
failures
approval)
D Development time Weeks
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New Equipment Development
Approach:
OBJECTIVES METHODOLOGY
1. Development lead
time reduction
2. Early stabilization
a.
b.
a.
Concurrent Development
Standardization
Implementation of all
`
of OEE with applicable MPs from
more pillars in the new
productivity machine
a. Implement all the kaizen
as past learning for new
Equipment
3. Increase Quality Development.
(Reliability) of the b. Increase the parameter
machine tested on the newM/C
c. Reduce the no. of
Defects due to
equipment
a. Optimization of cycle
time and consumable
4. Cost per piece
usage based on input
reduction.
from MP sheets and
CFT meeting.
a. Applicable MP sheets
5. Zero accidents
of similar machines.
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New Equipment Development Steps
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New Equipment Development System Flow Chart
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FLOW CHART INPUT/STANDARDS / RESPONSI
STEP CHECK POINTS DOCUMENTS -BILITY
CORPORATE ME / TE / ENGG. PRODUCTION
A. Corporate targets 1.Corporate plan from MD
ME from
1. EQUIPMENT CORPORATE - New products 2.Schedules from PR
management
OBJECTIVES -Quarterly sales meetings
PLANNING
B.Manufacturability 3.Input drawing from R&D
study-New products 4.Make/Buy list
EQPT PLAN ME
1,2,3,4,5 C. Make :in-house
PREPARATION 5.Cell plans
Buy: from vendor
D.Existing capacity
(Inplant/ other plants) ME,
REVIEW -New m/cs required Production,QA
E.Target improvements
in P,Q,C,D
ME from
CONCEPT F.Budget & schedule
Management
APPROVAL
BUDGET 5,6,7 ME
PREPARATION
ME from
BUDGET
Management
APPROVAL
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WHAT IS LCC ?
IT IS THE TOTAL COST OF:
-A PRODUCT
-AN EQUIPMENT OR
-A SYSTEM
OVER THE WHOLE OF ITS LIFE
IN TPM IT IS CONSIDERED AS A VERY IMPORTANT DECISION MAKING
TOOL
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Concept of Life Cycle Cost
Cost of purchases
(R&D, Production
Training
Cost Test, Support
and Service
Equipment (Personnel) Cost
Cost
Facility and
Equipment Cost
Logistical Transport and
Support and Cost Handling Cost
(Supplies,
Transport
Technical
Replacement and Information Cost
Scrap Cost
© JIPM, 1987
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Machine: ABC
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Thank you
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