DRAFT SOP (IN WORKING DOCUMENT) ON

NEW PRODUCT AND PROCESS DEVELOPMENT

Purpose: To define and document a procedure for new product development.

Scope: This procedure applies to precast concrete products:

a) New product development (e.g. Segmental retaining wall)

b) New segment development (e.g. Sewage Treatment Plant, Building)

c) Modification of existing product (e.g. Different size of Box Culvert)

d) New Technology development (Coupler jointing, fiber concrete)

e) New service development (Post tensioning, Installation)

Project Committee:

The Managing Director applies for initiation of the project.

New Product Technical Committee is responsible for designing and documenting inputs and outputs
of design and development activities.

NPTC comprises of:

1. One Executive Director (Technical)

2. Head / General Manager (Operations)

3. Head / GM (Procurement)

4. Manager (Quality Control)

5. Head / GM (Design , Method Development & Validation)

6. Head / Senior Manager (Production)

7. Head / Senior Manager (Regulatory Affairs/Communication + Documentation)

8. Head / Manager (Product Development)

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Initiation of Ideas

New Product ideas / requirements

The new product ideas / requirements are forwarded to

1. Managing Director (MD)

2. New Product Technical Committee (NPTC)

Method of communication: Email to [email protected]

Source of New Product Ideas / Requirements

1. Internal Sources: R&D & Employees

2. External Sources: Customers | Competitors | Distributors | Suppliers | Outsourcing firms |

Design Firms | Product Consultancies | Online Collaborative Communities | Online Opinions

Derivation of New Product Ideas

New product ideas are derived from either one or more of the following groups:

• Suggestions to New Product Technical committee

• Brainstorming sessions arranged by MD

• Market survey and literature

• Competitor’s product samples

• Customer requirements

• In-house designing efforts (from original research Products)

Idea Screening

These ideas and requirements are reviewed by the ED (Technical) and VP (Marketing), recorded on
Project Initiation Form approved by the MD and is forwarded to EDT for further working.

Preliminary Elimination:

1. Promising Ideas

2. Marginal Ideas

3. Rejected Ideas

Screening:

Basis of screening

1. Estimate of market size

2. Product Price

3. Development Time and Costs

4. Manufacturing Costs

5. Rate of Return

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Concept Development and Testing

Ideas selected after screening go for Concept Development

Design & Development Planning: Executive Director Technical [EDT] prepares Design and
Development Plan for the project indicating the design phases, departmental interfaces during the
design process, tentative planned duration of each design phase, etc. The tentative durations are
only minimum projected durations and may vary depending on the availability of resources and
personnel. The plan is forwarded to Manager Product Development along with the Project Initiation
Form for execution.

Product Concept Proposal

1. Product User / Target Customer

2. Product Application / Main and consolidated uses

3. Primary Benefit of the Product / USP

4. Time of consumption

5. Testing / Check with group of customer for Appeal

Marketing Strategy Development

Overall:

1. Target Market

2. Planned Value Proposition

3. Product Positioning

4. Sales

5. Market share

6. Profit Goals

Short Term Outline:

1. Planned price

2. Distribution

3. Marketing Budget

Long Term Plan:

1. Planned Long run sales and Profit Goals

2. Marketing Mix Strategy

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Literature survey and innovator/competitive product development analysis

Literature survey of available methods, similar applications, similar products, related testing, etc.
with references if prepared by Manager Product Development and submitted to EDT.

Manager Product Development checks innovator / competitor’s product or technology and submits
report to EDT.

EDT provides suggestions / recommendations and returns the report.

Design Inputs and Specification Plan

Product Development Team (PD Team) under the supervision of Head/Manager - Product
Development starts working on the tentative design of the intended product with 3D
Concept/Visuals and required inputs for Design and Development.

These inputs may include:

1. Material properties

2. Loading criteria

3. Environmental criteria

4. Other functionality related criteria (e.g. Fire safety)

5. Handling criteria – Product weight limitations and TEP availability

6. Loading and Transportation criteria – For product size

7. Formwork criteria

8. Other operations criteria

NPTC approves design inputs from Product Development Team and supports in necessary data
capturing.

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Design and Development

Product Development Team (PD Team) shall consider the following and prepare a design report:

1. the nature of design and development activities,

2. duration required,

3. nature of complexity,

4. required process stages including reviews,

5. verification and validation activities,

6. responsibilities and authorities in design and development process,

7. internal and external sources required,

8. need for involvement of customers,

9. design controls,

10. control interfaces among other departments,

11. requirements for future provisions of products and services,

12. level of control expected from design department

13. level of control expected from other departments, customers and other interested parties

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Advanced Production and Quality Planning

Once the product design is reviewed, verified and validated, the NPTC takes decision on order of
formwork and proceeds for the Advanced Production and Quality Planning (APQP Process).

Once the formwork is ordered, the item code is opened in SAP.

Design FMEA (Failure

Customer order Customer specifications Ability Appearance
mode and effect analysis)

Inspection method,
Design review Design verification plan Quality Planning
equipment and tools

Inspection/Control Plan Prototype item production Design – Drawing and Confirmation of

for prototype and inspection specification manufacturing feasibility

Process flow chart and Inspection equipment Preproduction/ Pre release

Process FMEA
mass production layout capability control Plan

Logistic Concept including Mass production

Process instructions Production first trial run
packaging material inspection plan

Initial process capability Technical test on

Initial sampling inspection
study Production items

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Design and Development Documented Output

1. Design Report

2. Specifications

3. Raw material

4. Quality Assurance and Testing Procedure

5. Packaging and Promotional Materials

Production Part Approval Process (PPAP)

To be completed….

Stability study

1. GM (Operations) prepares a stability protocol for the first 3 samples of products. An SOP may
be developed.

2. Stability study may be carried out and reported every 6 months. Any deviations/failures may
be recorded, and the results maybe intimidated to EDT.

3. EDT holds a Design Review Meeting with Team where probable causes of deviation / failures
are discussed and modification in the product are proposed and approved.

4. The decisions / modifications in the intended product are implemented through Process
revision Form.

Design and Development Reviews

Minimum 3 reviews:

1. Design review on completion of Design by NPTC

2. QA Review on completion of first trial/mock
3. Third review after completion of stability studies by NPTC