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