NPI process
NPI Process
BNMT
P04/2004
Product Project Management Flowchart --
CE Process PE Process
MFR/Cost Improvement
Product PE Project Team in TF
1 Mon
Product Review Meeting
--FOPM Team
New Product Project Team
(CE Team) in TF
Product improvement activities --MFR, Cost, Volume...
New Product Project Plan + Impl.
--FOPM
Product Management in TF--FOPM
Product Project Operation CE Team Organization E0-E4
BNMT
PPL
Comp.
Quality
Testing Engineer
Testing Maintain
Lab Engineer
IE
ME
Diagnostic
Sub-project leader
Diagnostic process
PSE
Repair Tech.
Lab Engineer
Testing
Sub-project leader
Design for PT
FA
Sub-project leader
Design for FA
Supply
Quality
Control
Supply
Line
Control
Purpose of the
New Product Introduction
New Product Introduction activities are carried out in the factories by factory resources to establish verified manufacturing capability and successful rapid factory Make Ramp-Up for new product
Factory Make Ramp Up and Handover Factory Make Ramp Up and Handover
NPI Project Planning in target factory NPI Management
Targets/plan proposal
Targets/plan proposal Targets/Plan commitment & approval
Targets/Plan
commitment & approval Manufacturing Process Verified
Reporting factory status regulary to OPM & Factory Management
Program Changes CI Project Changes
Line/Process Verification
Implemented Manufacturing Process for new product
Board Assembly HW & SW Implementation
Incoming Material Package Implementation
Requalification Implementation
NPI Planning Information communication Product Program Factories Plan Proposal Factory NPI Plan:?What to do ?When to do ?Who is doing
Manufacturing Process Design Implementation
New Product Introduction Process –Top Level
Responsibility of the Factory CE Project Team
The Purpose of the CE is to develop the product and verify the components and process to manufacture the product to be
The Purpose of the CE is to develop the product and verify the components and process to manufacture the product to be Factory NPI Project Team is responsible that CE-process
guidelines are followed in factory NPI activities. The main mission for NPI-activity is to build up verified production capacity to factory and have the responsibility of factory ramp-ups. FOPM is leading the NPI-activity in factory and therefore considered overall responsible.
activities
Factory NPI Team is responsible that CE-process guidelines are followed in factory NPI activities. The main mission for NPI-activity is to build up verified production capacity to factory and have the responsibility of
factory ramp-ups. FOPM is leading the NPI-activity in factory and therefore considered overall responsible. More detailed responsibilities and main activities are:
?Factory OPM
The Factory Operation Project Manager (FOPM) is the factory-based project leader that coordinates, leads, and directs the Factory team’s activities.
The FOPM is normally considered to be responsible for these tasks even though this person normally has a factory team to
help perform tasks.
?Naming Factory Project Leader to a product program
Factory Management names a FOPM between E-1-E1 (when official plant focus decision is available)
?Build up contacts to product program
FOPM is the main contact to product program is OPM/OPL
?NPI team resource planning and gathering (FOPM coordinate)
NPI team resource comes from factory line functions -allocations are done by line management.
Activities
?NPI activity target setting
Harmonizing program and factory targets (common goal/targets)
Main measures are based on global Ramp-Up measures
Participating CI and MPI plan creation together with Program OPM
?NPI activity kick-off
Product Program is responsible for arranging
FOPM is responsible for arranging NPI kick-off in factory together with product program (OPM/L)
Factory NPI team are important to participate in program kick-off, factory management team can also join the meeting if needs
?NPI Training
FOPM drive to make the overall training plan together with Program and factory NPI team
Sub-project leader make detailed training plan for each function team
Training plan should cover all relative production line people
?Capacity Implementation in factory
FOPM is in charge of capacity implementation activities in the factory, including factory specific investment plans.
CI includes all needed deliverables which are described in NPI /CE-process to be done by factory personnel Responsibility of a new product's NPI/PV builds, creating factory NPI/LV/RU report
?Ramp-up planning
Ramp-up planning together with factory organizations and product program
Participation to factory volume planning
?Ramp-up in factory
FOPM is in charge of factory ramp-up(s) in factory (includes planned copy ramp-ups in factory)
Ramp-up follow up according to plans/targets
FOPM reporting of ramp-ups to factory management and product program (OPM/L)
FOPM lead the factory team in developing the CE to PE Operations hand over plan together with OPM/Ls
?Change management (CR/EO) in factory
FOPM gathers names in the factory that will be listed in CR/EO approval cycle (engineering/materials/quality,/etc) FOPM is the factory’s main approval authority in factory after E2
?Milestone reviews in factory
FOPM leads factory team in conducting sub-reviews and factory-review and reporting in factory and program FOPM or deputy possible participate to program milestone reviews
?NPI team leadership
Develops information sharing processes and methods
Facilitates regular meetings with factory NPI team for plans/actions/etc.
FOPM and sub-team leaders monitor activities against plans
FOPM and sub-team leaders take responsibility in decision making
Recognises customer needs
FOPM and sub-team leaders coach, train, and guide rest of NPI team
?Reporting to Factory Management & OPM/L
FOPM reports to factory and program regularly based on agreed schedules for both customers
FOPM and team provide factory-specific NPI closing and final report ( lessons learnt ) in factory
FOPM and sub-team leaders provide factory-specific information that is required in program milestone status reports
?General operation coordinating and information sharing
FOPM has understanding of all NPI activities in factory
FOPM is communication channel between product program and factory
?NPI Team members' responsibilities
Implement own tasks according the NPI Plan
Reporting and information sharing inside NPI Team in factory Planning own tasks
The Responsibilities of BA Product Engineer for
NPI Build
BNMT
P04/2004
The Responsibilities of BA Product Engineer for NPI
Build
1.Nominated BA engineer to be in product CE team as BA responsible key person, the one whom to organize
BA sub-team for this product;
2.Contract the product’s Program BA specialist to get BA basic related information;
3.Get samples and basic manufacturing document from Program;
4.Get the DFBA(Design for Board Assembly) file from Program;
5.Make Partlist, inspect drawing according to BOM and DFBA file;
6.BA sub-team finish FMEA and Control plan;
7.Locate NPI production line and layout, finish investment and capacity calculation, training plan;
8.Checklist ready to all members;
9.Machine tooling(printing,placement and underfill), jig, nozzle, stencil, feeder and special rework jig
designing and ordering;
10.Checking material of Key components’and ordering things’status;
11.Production preparation arrangement, training and meeting with all team members(process owner, line
leader, key operator, operators);
12.Update inspect drawing, Partlist and machine setup sheet;
13.Machine(printing, placement, oven profile and underfilling) program preparation;
14.Line changeover and setup;
15.Trial board production;
16.Inspection and testing result analyse and corrective actions;
17.NPI production co-parallel production with FA/Testing line, corrective actions according to feedback;
18.Review meeting;
19.NPI report and lessons learn and sharing meeting
Factory specific Manufacturing Process Designs
New Product Introduction
NPI Team resourcing
NPI project kick-off
Participation to CI milestone reviews & responsible for NPI reviews in factory NPI project target setting
NPI team leading in factory
Build & maintain contacts to Program (OPM/L)
Resources allocated to Pgm pFMEA
Product/process related trainings in factories (plan & execution of plan)
Change management (CR/CN)
Product specific pFMEA creation in factory
Manufacturing process implementation responsibility/ Factory NPI Project plan
PC PV
Reporting to factory Management and OPM
?Factory Project Leader assigned to a product program
?OPM request FPL from Factory Management when plant focus is available
?Factory Management responsible to assign FPL
?Build & Maintain contacts to product program
?FPL is main contact to program OPM/L -> should maintain list of contacts & responsibilities
?NPI team resource planning and gathering (FPL coordinate)
?FPL plan (with OPM guidance) needs of NPI team and request resources from Factory line functions ?Resources allocated from factory line function management
?Planning of NPI team member's time allocation for the NPI activity
?NPI project kick-off
?Product Program is responsible for arranging official “factory kick-off meeting”
?FPL is responsible within the factory NPI kick-off (work with OPM/Program in arranging)
?Factory NPI team and Factory Management team are critical participants in program kick-off
?Factory is responsible for communicating factory-specific and/or regionally-specific requirements/needs
?Could include issues such as: import/export, customer-specific, etc.
?NPI activity target setting
?Harmonizing program and factory targets (common goal/targets)
?Main measures are based on global DSN RU measures
?Participating CI and MPD plan creation together with OPM
?Should be detailed information to include ramp-up order, which factory(s) will be included in E3/E4 reviews, what level of program support will be provided, etc.
?Factory-specific NPI plan (Create & Maintain )
?FPL makes factory NPI-plan together with NPI team members based on program plans
?Project plan should include all activities, responsible persons,& estimated completion dates
?Including such things: DFM work,pFMEA work,CER’s, equipment ordering, Process conversion, Process verification
?This is supplied to product program by each factory (Program responsible for identifying differences between factories)
?FPL & NPI team should maintain/use project plan to manage their work & identify needs/gaps ?Factory-specific manufacturing process design
?Based on Product Program & factory targets and MPD sub-process outcome
?Factory NPI Team create & maintain factory-specific process design (line design) and capacity calculations
?Factory responsible for communicating process details to Program and any deviations from Program specifications
?Manufacturing Process Implementation
?FPL and NPI Team is responsible for Manufacturing process implementation/ process modification for new product in EnO&SOp
?NPI Build planning
?FPL plans/arranges NPI builds together with NPI team members, NPI-line manager/ Production manager and product program (OPM/L)
?Factory-specific build definition/targets to be defined between Program and Factory (FPL+OPL/M) based on Program build-plan & Factory needs
?NPI build responsible
?Factory NPI team responsible for executing build per build definition
?FPL (or deputy) should manage/lead NPI builds
?OPM/L is build approval authority –have achieved desired/needed results
?Resource allocation for program pFMEA before E2
?Factory NPI team works together with Program to complete program level pFMEA
?Responsible for product specific pFMEA and Control Plans in factory after E2
?FPL approves factory specific pFMEA/control plans in factory.
?NPI team members modify pFMEA against factory specific line –creation of CP
?NPI team members creates/updates production line work instructions
?Responsible for product related training inside factory
?FPL creates a training plan with OPM/L
?NPI sub-team leaders should create sub-team level training plans and provide to FPL
?FPL approves the training plan from NPI team (training coordinator arranges training according to training plan)
?FPL is responsible to ensure that all necessary trainings for factory are planned/arranged (target setting, follow up).
?OPM/L should be considered “authority”to approve training plan based on program needs/targets
?Factory MAKE Ramp-up planning
?Ramp-up planning together with factory organizations and product program
?Participation to factory volume planning
?Update NPI project plans based on latest RU plans
Responsible for change management (CR/CN) in factory
?FPL gathers & maintains list of factory names that will be listed in ECR approval cycle
(engineering/materials/quality,/etc)
?FPL responsible for contacting Program document controller of any changes
?FPL is the factory’s main approval authority in factory after E2
?FPL responsible for ensuring all applicable ECN implementation records are complete (as applicable) Responsible for milestone NPI reviews in factory
?FPL leads factory team in conducting sub-reviews, NPI reviews, and reporting in factory and to program OPM
?FPL or deputy participate to program CI milestone reviews
?FPL and sub-team leaders provide factory-specific information that is required in program milestone status reports
Reporting to Factory Management & OPM/L
?FPL reports to factory and program regularly based on agreed schedules for both customers
?FPL and team provide factory-specific NPI closing and final report (lessons learned) in factory
FPL & NPI Team leadership
?FPL & Team develop information sharing processes and methods
?Facilitate regular meetings with factory NPI team for plans/actions/etc.
?FPL and sub-team leaders monitor activities against plans
?FPL and sub-team leaders take responsibility in decision making
?Recognises customer needs
?FPL and sub-team leaders coach, train, and guide rest of NPI team ?FPL has understanding of all NPI activities in factory
?FPL is primary communication channel between Program and Factory
NPI Team members' responsibilities
?Plan & implement own tasks according the NPI Plan
?Reporting and information sharing inside NPI Team in factory Factory Management responsibility
?FPL Nomination
?Resource allocation to factory NPI Teams
?Resource competencies & skills development
?Guidance to NPI work in factory