part 5 of 7 part Case Study

1 Product development

Luxury brand Case Study

2

Notes

3

November 2012

Max Ruckman, Black & Decker HHI

Project Team

Luxury Brand

Business

Development

Case Study Part 6-8

www.maxruckman.com

4

Phase vi

produ

ction

all agency listings and quality plans are complete and on the line

Bulk build & test

Definition

first full production lot

after the final pilot and

conducted using

production tooling, by

trained persons

approved capital equipment

Bulk build & test

Inputs

clean pilot lot i.e. no product design, tooling or process changes

successful pilot lot test results

statistically significant reliability assurance test results from the laboratory and field

ramp up goals

production plan

launch plan agreed upon by team and marketing

confirmed product cost

productivity / waste & variances

Bulk build & test

Actions

build product

safety / process & variances

inventory

measure to all promised deliverables

quality first time pass & finished stock audit

service level

bulk production review: program manager

to hold monthly post production review,

includes resident engineer

Bulk build & test

Deliverables

salable product for

release to distribution

action plan to address misses

second pilot of “Product X” was run on “date” at the

manufacturing facility consisting of 120 units

Pilot lot build

summary

this product is very similar in construction to the

existing “product y” products being built at the

manufacturing facility, and therefore the majority of the processes already in place were carried

forward when this product was built

Pilot lot build

summary

there are three exceptions in the component assembly area

Pilot lot build

summary

the operators experience minimal disruption or problems when assembling these components

Pilot lot build

summary

mechanism

design was changed to eliminate “problem A” that occurs in “product X” when under extreme environmental conditions

a plastic spring retainer was replaced with a powdered metal plate and six steel pins.

no action required

Pilot lot build

summary

this must be closely monitored by all team members

Pilot lot build

summary

final recommendation: to insure

the product meets the highest

quality standards a

comprehensive audit plan must

be followed, with special attention to the sub-assemblies

add other issues as needed

Pilot lot build

summary

cartons

all artwork completed

all revisions and changes were made to carton art work to new

information per marketing request

any other changes required to packaging

Pilot lot test

Packaging example

“product x” products have been through several different builds,

each time with major improvements to the durability of the design

Pilot lot test

Product testing summary

the following schedule summarizes the builds

august 2011 prototype build 20 units

october 2011 esl 1 46 units

january 2012 esl 2 145 units

march 2012 pilot lot 1 80 units

april 2012 pilot lot 2 120 units

Pilot lot test

Product testing summary

tested 54 units including all builds

Pilot lot test

field testing

typical uses: door installation

typical users: home builders, DIYer’s

logged over 5,250 days in the field

Product testing summary

application based reliability testing

tested approximately 120 units on destructive cycling test

applications: list uses tests performed

Pilot lot test

in-house testing

remaining tests: in the process of completing all rig testing for a complete

analysis of the pilot lot units continuing application testing until failure

Product testing summary

agency certification

all testing has been

completed and certification

was received if applicable

Pilot lot test

Product testing summary

Phase vii

distri

bution

audit of product to confirm its acceptable for release to distribution

Sqa confirm

Definition

audit results

test results

engineering test results

Sqa confirm

Inputs

supply standard

manufacturing procedures as

dictated by audit results

Sqa confirm

Actions

release the product to distribution on concluding a “good” result

Sqa confirm

Deliverables

replacement parts must be available in the service

warehouse before product introduction so they can be

used by the service and reconditioning centers

Service spares

Definition

manufactured cost of spare parts

Service spares

Inputs

complete engineering BMO & related part drawings

product sales forecast

forecast of replacement parts inventory using in-house testing results

structure of all part masters in supplier database

receive, inspect and

place replacement

parts into inventory

Service spares

Actions

structure service part masters

develop service BOM

develop list of recommended initial parts order quantities

determine initial parts order quantities

place orders for replacement parts

ready-to-order

replacement parts

inventory in service

base warehouse

Service spares

Deliverables

Phase viii

Program

Target

scoring

access performance of existing similar product to carry-over good features and avoid

recurrence of “old” problems

Post audit

Definition

assist in provision of product feedback

(after-the-sale)

request from product team for

feedback on current product

Post audit

Inputs

request from

project team to add product to

early warning

discuss performance of existing similar product with project team (by service repair and/or reconditioning technicians to identify strengths and weaknesses of current similar products)

Post audit

Actions

provide feedback to project team on after-the-sale performance of the product

add product to early warning program

product feedback information on similar, current product

Post audit

Deliverables

after-the-sale feedback on new products

November 2012

Max Ruckman, Black & Decker HHI

Project Team

Luxury Brand

Business

Development

Case Study Part 6-8

www.maxruckman.com

37