New Product Introdution NPI Guidelines新产品引进指导.docx

New Product Introdution NPI Guidelines新产品引进指导.docx

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NewProductIntrodutionNPIGuidelines新产品引进指导

1.0  OBJECTIVE/PURPOSE

Thisdocumentprovidesasetofguidelinesfortheintroductionofnewproductsthatcanbeadaptedtoeachsite’suniquerequirementsandincorporatedinlocallycontrolleddocuments.

2.0  SCOPE

ThisGuidelinecoverstherequirements,process,responsibilitiesandkeyelementsrequiredfortheintroductionofnewproductsintomanufacturing.Theseproductscanbedesignedeitherinternallyorexternally

ThisGuidelinecoversPCBAssembly,TestandSystemIntegrationactivitiesthattakeplaceprimarilyafterthebusinessdevelopmentandproductdesignphases.

AnyproductthatismanufacturedforthefirsttimeinaFlextronicsNewProductIntroductionCenterorFlextronicsFactoryshouldfollowthisguideline.

3.0  DEFINITIONS

NewProduct-Forthepurposesofthisprocedure,aNewProductisdefinedasaproductthatisintroducedforthefirsttimeatFlextronicsand/orrequiresanengineeringverificationordesignvalidationandprototypebuildactivity

ProductTransfer-Forthepurposeofthisprocedure,aproducttransferreferstoaproductthathasbeenpreviouslybuilt,eitherinternalorexternal .ThisproducthasalreadyhadadesignverificationandprototypebuildandonlyrequiresaPVandPilotbuildtoverifytheprocesscapabilityatthemanufacturingsite. （OnceaproductleavestheDVandmovestothePVphase,thisisconsideredinProductTransfermode,butmaystillbeunderthecontroloftheNPIorganization,dependingonlocalbusinesspractices）

EV–EngineeringVerification

EVUnitsareengineeringsamples.Unitsareusedtoverifythefunctionalityofthedesignandconformancetodesignspecifications.Typically,thedesignandformfactorisnotfinalized.

Theseunitsmaybebuiltinalabenvironmentorinaprototypecenter.Quantityisdeterminedbymutualagreementwiththecustomer,butistypicallylessthan10,andmaybeofhigherquantitiesforhighvolumeproductssuchastelephones.

Theseunitsaresometimesusedbydesignengineering,marketing,andsoftwaredevelopment.Theunitsaretypicallynon-revenuegeneratingforthecustomer.

DV–DesignValidation

DVUnitsareinthefinaldesignandfullydebuggedform.Theformfactorisfinalized.Unitsareusedforfinalvalidationtestingoftheproductforconformancetodesignandproductspecifications.

TheseunitsareoftenbuiltonaprototypelineorNPIcenter,butshouldberunonthesametypeoflinethatvolumeproductionwillbeusing.Thebuildquantityisdeterminedthroughmutualagreementwiththecustomer,butisoftenlessthan100,andmaybemuchhigherforproductssuchastelephones. 

Theseunitsaretypicallyallocatedtodesignengineering,qualityengineering,testengineering,manufacturingengineering,softwaredevelopment,andmarketing,andmaybesubjectedtodestructiveleveltesting.

Theunits,oftencalledthePrototypeRun,aretypicallynon-revenuegeneratingforthecustomer.Conclusionofthisphasemayinvolveareviewmeetingwiththecustomerandtypicallyareportisprovidedsummarizingtheresults.

PV–ProcessValidation

PVUnitsarethefinal,customerreadyunitsbuiltonthedesignatedproductionlineintheselectedproductionfacilitytovalidatetheproductionprocess,determineprocessbaselinesforSPC,testyields,etc.andidentifyimprovementopportunities.

Thebuildquantityisdeterminedthroughmutualagreementwiththecustomer,butcanoftenbegreaterthan100.

PVunits,oftencalledthePilotRun,aretypicallyrevenuegeneratingforthecustomer.Conclusionofthisphasetypicallyinvolvescompletionofsomecombinationofthefollowingbasedoncustomerrequirements:

amutuallyagreedvalidation/qualificationprotocol,anexitmeeting,andafinalreport.

Abbreviations:

AML/AVL–ApprovedManufactureList/ApprovedVendorList

BOM–BillofMaterials

DFx–DesignforManufacturing,Testing,andAssembly

DFM-DesignforManufacturablity

DV–DesignValidation

ECN–EngineeringChangeNotice

ECO–EngineeringChangeOrder

EDI–ElectronicDataInterface

EV–EngineeringVerification

FAR-FirstArticleReport

FAI–FirstArticleInspection

FMEA–FailureModeandEffectsAnalysis

GPM–GlobalProgramManager

GR&R–GaugeRepeatability&Reproducibility

ICT–In-CircuitTest

LOA–LetterofAuthorization

MOQ–MinimumOrderQuantity

MPI–ManufacturingProcessInstruction

PV–ProcessValidation

PM–ProgramManager

4.0  REQUIREMENTS

Thefollowingshouldbecompletedand/oravailablepriortothestartofaNewProductIntroduction:

4.1 Customer’sfinancialpositionhasbeenapprovedbyBusinessDevelopmentinconjunctionwithCorporateFinance.

4.2 ManufacturingcontractnegotiatedandsignedbyBusinessDevelopmentandCustomer.

4.3 CompletePriceQuotationwithassociatedpricingback-upandassumptions.

4.4 FinancialexposureforthejobiscoveredbyaPOorMfg.Agreement.

4.5 Theconceptphaseoftheproducthasbeenfinalized.

4.6 IssueswithCustoms,export/Importrequirements,tradeactimplications,dutyrequirementsetc.havebeenresearchedandunderstood.

5.0  TRAINING

TrainingishighlyrecommendedforProgramManagersinvolvedintheintroductionand/ortransferofproducts.Trainingoptions:

FlextronicsUniversity,presentationbyasubjectmatterExpert,useoftheoverviewoftheNewProductIntroductionandProductTransferprocessFBP-ENG124locatedintheeLibrary.

6.0  GENERALRESPONSIBILITYANDAUTHORITY

Thesitethathasbeenassignedtheresponsibilityfortheproduct,mustdesignateapersontobetheprimaryfocalpointwiththeappropriateresponsibilityandauthoritytoensuresuccessfulcompletionwithintheorganization.

Thedesignatedpersonandteammustprovidethenecessarysupportastheproductmovesthroughthevariousphases.

6.1   BusinessDevelopment/Programmanagement

OResponsibleforCompletingthebusinessdevelopmentactivitiesthatincludescustomerpre-qualification,RFQ/RFP,ManufacturingAgreement,customerinterfaceonnewbusinessopportunities,etc.AssuresProgramManager（s）havebeenassignedtoassumeresponsibilityofNPIprogram.

O Apersonshouldbeassignedtheleadershiprole,typicallythisisaProgramManager.ThispersonisresponsibleforFacilitatingandcoordinatingtheentireNPIactivitiesandinterfaceswithcustomerandensuresrequirementstobuildtheproductaremet.Holdsnewproductstartupmeetings,NPIReadinessreviewmeetings,NPIPostBuildreviewmeetings,andProductTransfermeetingswithrelevantdepartmentsand/orcustomer.Providesfinalprotoandpilotreportstothecustomer.

6.2   Process/ProductEngineering

o    EnsuresthenewproductsaremanufacturablebyperformingDFManalysisandcomparingcustomer’srequirementswithinternalcapabilities.

o    Providesrelevantworkinstructionsandnecessarytoolingtobuildthenewproducts.Supervisesandmonitorstheactualbuildactivities.Interfaceswithcustomerforanyprocessrelatedissues.Ensuresthenewproductsaretransferabletovolumefactory.

6.3   TestEngineering

o    DevelopsTestStrategythatincludesICT,MDA,FT,SystemTest,StructuralTest,e.g.Laminography.

o    EnsuresthenewproductsaretestablebyperformingDFTanalysisandcomparingcustomer’srequirementswithinternalcapabilities.

o    Providesrelevanttestinstructionsandnecessarytestfixture/instrumenttotestthenewproducts.CreatedTPI.Supervisesandmonitorsthetestactivities

o    Ensuresthenewproductsaretransferabletovolumefactory.

6.4   QualityEngineering

o    Ensuresthenewproductsmeetcustomerrequirement/specification.

o    PerformsinspectionandverificationasdeemedrequiredfromFMEA.

o    Providesrelevantworkinstruction,documentationandinspectionequipmenttoensureproductquality.PerformsFirstArticleInspectionandReport

o    Interfaceswithcustomerforqualityrelatedissues.Ensuresthenewproductsaretransferabletovolumefactory.

6.5   Materials/Logistics

Procurespartsrequiredtoruntheprotoandpilotbuildsofthenewproduct.Pipelinesmaterialsforfutureproductionruns.

ResearchanddevelopplansandaddressanyissuesregardingCustomsandtrade,export/import,taxes,fees&duties,embargos,shippinganddeliverymethodsetc.

6.6   Planning

MasterScheduler

Themasterschedulershouldfocusonmaterialavailabilityandfactorycapacity. Themasterschedulershouldinterfacewithprogrammanagement,asaconduittounderstandingcustomerneedswhenloadingtheplan. ThemasterschedulershouldberesponsiblefortheaccuracyoftheMPSload,andSchedulesthetargetprotoandpilotbuildrundates.

Planner

Theplannershouldfocusonthedailyoperationsoffactorymanagementwithemphasisonbothinternalandexternalcustomersatisfaction. Thispositionshouldberesponsibleforcreatingandexecutingafactoryschedule. Thispositionshouldalsoberesponsibleforanyshort-termmaterialstatusrequests. 

6.7   Production

ExecutesbuildperMPIandTPIandprovidesfeedbacktorelevantdepartmentsforManufacturabilityandTestability.

6.8  DocumentationServices

ReceivesandmaintainscustomerdocumentationinDocumentControlareaand/orAgile.Distributescustomerdocumentstorelevantdepartments.Ensuresonlycurrentandcontrolleddocumentationaredistributed.

6.9   Environmental,Health&Safety（EHS）

o  EvaluatesallEnvironmentalAspectsandLaborHazardsrelatedwiththeNPI,inordertoensurethecompliancewiththelegalrequirementsassociatedwiththesetopics,environmentprotectionandemployeesafety.

o    Receiveandimplementontheprocess