Flawless Product Launches

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					                 ENTERPRISE QUALITY AND COMPLIANCE MANAGEMENT SOFTWARE



                  MFG/PRO
       Midwest User Group
       Fall Conference 2006




     Flawless Product Launches


                                                     PRESENTED BY
                                                 John M. Cachat, IQS
                                                    Dave Doyle, QAD
MMUG Sep 2006
   • The current “state of the art” in most companies
     include MS Project & MS Excel. These tools are
     personal productivity tools – not enterprise
     business systems.

   • This presentation will discuss the technology
     available to execute product launches, not just
     track how far behind you are.

The system must do the work – not just report on it.



                                               2
MMUG Sep 2006
                Product Launch Challenges

    •   What Tools We Have - What We Are Missing
    •   Identifying Waste In The Process
    •   Eliminating Waste In The Process
    •   Optimization – QAD And IQS Integration
    •   Flawless Product Launch - Keys To Success




                                              3
MMUG Sep 2006
        We All Know Poor Launches Are Costly
                       Or You Wouldn’t Be Here

    •   Products Arrive LATE
         • Competitor Gets Out First – Cell Phones – Lost Of Sales
         • Snow Blowers In June – Who Cares – No Sales
         • Cars Without MP3 Players Or IPod Connectors
    •   Is The Challenge Innovation Or Execution ?
    •   No One Plans To Be Late
         • They Knew What It Took To Produce The Cell Phones
         • The Plan Showed Snow Blower Delivery For December
         • Design Engineers Have IPods And Are Frustrated Too



                                                                4
MMUG Sep 2006
                Product Launch -- Its About Execution

         OYAMA, Japan – August 25, 2006| “Toyota may delay the
         launch of some of its new models, the company’s president
         said today, as the world’s No. 2 automaker tries to improve its
         quality process in order to reduce a spate of recalls that is
         threatening its reputation”

         “Watanabe said that the emphasis was on making sure
         quality procedures were properly carried out, rather than
         on how much time the process took.”

         Toyota’s shares fell 60 yen, or 0.95 percent today.



                Product Launch – It’s A Bottom Line Issue

                                                                   5
MMUG Sep 2006
   What Is Flawless Launch ?

   •   It Is About Optimizing Constraints
           • Time
           • Quality
           • Cost                                Quality

   •   Identifying & Resolving Flaws
          • Reduce Variation
          • Eliminate Waste                 Engineering    Cost

   •   Life Cycle Process
          • Not Departmental                       Cost
          • Not Documents




                                                            6
MMUG Sep 2006
   What Works – What is Missing
                            What is my risk?   Is the Supplier
       Where is the FMEA?                       Performing?
   What is the status                            Is there a control plan?
    Of my ECN?
                                                        WHY is the
What are the key                                       Part on hold?
Characteristics?


     Engineering                                          Scheduling
       Bill of
                                                        Labor and
      Material
                                                       Material Cost
       Document Vault
                                                        Shipping




                                                           7
MMUG Sep 2006
   Automotive Product Launch

   1.0 Plan and Define
                                            Project Plan

   2.0 Product Design and Develop             5 Phases
                                             23 Elements

   3.0 Process Design and Develop

   4.0 Product and Process Validation

   5.0 Feedback, Assessment, Corrective Action




                                                    8
MMUG Sep 2006
   Plan and Define Program
    1.1 Voice of the Customer                                  Project Plan
         1.1.1 Market Research
         1.1.2 Historical Warranty and Quality Information
         1.1.2Historical Warranty and Quality Information
         1.1.3 Team Experience
      1.2 Business Plan/ Marketing Strategy
      1.3 Product/ Process Benchmark Data
      1.4 Product/ Process Assumptions
      1.5 Product Reliability Studies
      1.6 Customer Inputs
      1.7 Design Goals
      1.8 Reliability and Quality Goals
      1.9 Preliminary Bill of Material                        14,000 Parts Per
      1.10 Preliminary Process Flow Chart                          Vehicle
      1.11 Preliminary Special Characteristics
      1.11 Preliminary Special Characteristics                        x
      1.12 Product Assurance Plan
                                                             100 Characteristics
      1.13 Management Support                                      Each

                The Devil Is in the Details


                                                                  9
MMUG Sep 2006
   Its 8:30 Monday Morning ….
          Do you know where your details are?
      2.1 Design FMEA
      2.2 Design for Manufacturability and Assembly
      2.3 Design Verification
      2.4 Design Reviews
      2.5 Prototype Build - Control Plan
      2.6 Engineering Drawings
      2.7 Engineering Specifications
      2.8 Material Specifications
      2.9 Drawing and Specification Changes
      2.10 New Equipment, Tooling and Facilities Requirements
      2.11 Special Characteristics
      2.12 Gages/ Testing Equipment Requirements
      2.13 Team Feasibility Commitment




                                                                10
MMUG Sep 2006
   Create and Use the Detailed Information

  2.1 Design FMEA
  2.2 Design for Mfg & Assembly
  2.3 Design Verification
  2.4 Design Reviews                   Opportunity
  2.5 Prototype Build - Control Plan      Gap
  2.6 Engineering Drawings
  2.7 Engineering Specifications
  2.8 Material Specifications
  2.9 Drawing and Specification Chgs
  2.10 New Equipment, Tooling Req
  2.11 Special Characteristics
  2.12 Gages/ Testing Equipment Req
  2.13 Team Feasibility Commitment




                                                     11
MMUG Sep 2006
                “But it’s on my project
                        plan …”

                 Project Management vs.
                    Project Execution

         Subtitle: The Tale of the Dead Docs



                                          12
MMUG Sep 2006
   Project Management vs Project Execution

                          •   Project Management tells you
                                 What, When

                          •   Project Execution
                                • Is doing the What

                          •   Execution Details are often
                              managed with attachments

                                  Attachments Become
                                  Dead documents that
                                    Generate Waste !




                                                      13
MMUG Sep 2006
   Documents and Attachments Versus Business Systems
   FMEA’s Have the Power to Manage Risk
                                       FMEA
                                     CHANGES
                              FMEA
                            ACTION
                             ITEMS             CONTROL
                                                 PLAN
                                               CHANGES
                   FMEA
                    RPN
                 ANALYSIS

                                                        FEEDBACK
                                                            TO
                CONTROL                               ENGINEERING
                  PLAN                               - Severity
                                                     -- Occurrence
                                                     - Detection




                             FMEA




                                                         14
MMUG Sep 2006
            Eliminate Waste
                  (Lean)


          Reduce Variation
                (Six Sigma)

                              15
MMUG Sep 2006
  Lean Product Launch
   Example AIAG Product Quality Planning Timing Chart
         Concept
   Initiation/Approval
                   Program
                   Approval
                                                      Protype      Pilot      Launch


       Planning

                         Product Design and Development

                              Process Design and Development

                                             Product and Process Validation

                                                                              Production

                              Feedback, Assessment and Corrective Action




                                                                                           16
MMUG Sep 2006
  Tremendous Amount of
  Non-Value-Added Waste in the Launch Process
   What you think it is



                          What it actually is




                                                What it should be




                                                         17
MMUG Sep 2006
  Example Reporting Nightmare



       This Is A HUGE Waste Of Labor To Create And
         Update Reports Because There Is Not An
        Enterprise Systems That Consolidates The
                    Data For Reporting

                        Even Worse,
           Every Department Has There Own Version


                                            18
MMUG Sep 2006
   Reduce Variation – Eliminate Waste




                      Opportunity
                         Gap




                                        19
MMUG Sep 2006
      Flawless Launch – IQS Bridge the Gap
  •    IQS fill the gap
       • Capture Details
       • Coordinate Details
       • Communicate Details


   •   Centralized Data Hub
        • One off Details
        • Legacy Systems


  •    Visibility
       • Tell me what, and WHY




                                             20
MMUG Sep 2006
                QAD and IQS Working Together




                        Customer Master
                         Supplier Master
                          Item Master
                        Employee Master
                      Change Management
                       Incoming Receipts


                                               21
MMUG Sep 2006
                NEW PROGRAM
                    APQP




                              22
MMUG Sep 2006
                APQP TASK LISTS
                - Customer
                - Internal
                - Supplier




                           23
MMUG Sep 2006
                EXAMPLE CHECKLIST




                             24
MMUG Sep 2006
   Engineering Portal




                        25
MMUG Sep 2006
                Management of Characteristics




                                        26
MMUG Sep 2006
                DESIGN FMEA




                        27
MMUG Sep 2006
                PROCESS FLOW




                         28
MMUG Sep 2006
                PROCESS FMEA




                         29
MMUG Sep 2006
                CONTROL PLAN




                          30
MMUG Sep 2006
          Engineering Change
              Management
   is one of the biggest challenges in
         the product launch and
              manufacturing

                               31
MMUG Sep 2006
   Engineering Changes – 3 Steps
     ECR - Engineering   Should We
     Change Request


     ECN - Engineering   Update Everything
     Change Notice


     ECO - Engineering   Do It
     Change Order



                                        32
MMUG Sep 2006
           Employee Suggestion Life Cycle
    Reject
   Revoke               PCR Creation
   Reroute

                 Route for Approval              Release
                                                 Notices
                Electronic Approvals
                               comments
                   NO
                           YES
                Release/Distribute


                 Convert to PCO

                                            33
MMUG Sep 2006
   Change Management Workflows




                                 34
MMUG Sep 2006
   Change Management – ECR, ECN, ECO




                                       35
MMUG Sep 2006
   Robust Change Management Options


   •   Single Change Request Against Multiple
       Products
   •   Single Product to Multiple Change
       Requests
   •   Single Product that Affects Multiple
       Products



                                         36
MMUG Sep 2006
           Product Change Life Cycle
    Reject
   Revoke               PCO Creation
   Reroute

                 Route for Approval                    Release
                                                       Notices
                Electronic Approvals
                               comments
                   NO
                           YES
                Release/Distribute        Dates   Planning
                                                  Systems

                 Implementation

                                                  37
MMUG Sep 2006
   Product Change Request Approvals


Workflow
Approved By List
    •   Includes Hierarchy
        And Stop If Not
        Approved Then
        Automatically
        Posted To Change
        Request When
        Product ID Is
        Entered

Email Notification Is
  Available

Escalation Available



                                      38
MMUG Sep 2006
  Identify and Eliminate Waste in the Launch Process

      What Current Process is
                                      Can you identify
                                    your current process?

                                    Use integrated tools to
                                          streamline.




                                 What it Needs to be




                                                   39
MMUG Sep 2006
  Incorporate Integrated tools
   Example AIAG Product Quality Planning Timing Chart
         Concept
   Initiation/Approval
                   Program
                   Approval
                                                      Protype      Pilot      Launch


       Planning

                         Product Design and Development

                              Process Design and Development

                                             Product and Process Validation

                                                                              Production

                              Feedback, Assessment and Corrective Action




                                                                                           40
MMUG Sep 2006
                    Summary
                Flawless Launches

   Single Source of Information is Critical
   Consolidate Stand Alone Tools
   Use Existing Enterprise Software Data
   Reduce Variation, Eliminate Waste
   Solve the Execution Problem




                                           41
MMUG Sep 2006
   Why IQS and Why Now?
   •   Off the Shelf Integration with QAD
   •   Tangible $ Savings Today
   •   Extension QAD Investment
   •   Document Authoring Solution
   •   Competitive Opportunity
        •   Faster Time to Market
        •   Lower Warranty Costs
        •   Early Warning System
        •   Lower IT Costs




                                            42
MMUG Sep 2006
     Flawless Product Launches


                 Q&A
                        IQS, Inc.
                19706 Center Ridge Road
                 Cleveland, Ohio 44116
                      440-333-1344
                      www.iqs.com


                                          43
MMUG Sep 2006

				
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