Product Management Phases

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					   The Product Development
 Cycle in Today’s Manufacturing
                   OVERVIEW
1.    Explain the product development cycle
2.    Define project management processes
3.    Relate #1 and #2
4.    Discuss the tasks behind each process
5.    Suggest simple communication tools
                  Bob Carson
                 March 11, 2004
                Product Development Cycle and Project
11MARCH04               Management Process
            Expected Outcomes

   Individuals will understand:
     product development in today’s industry
     processes of project management

     value of simple communication

   Individuals will recognize the value of effective
    project management skills in today’s product
    development cycle


                   Product Development Cycle and Project
11MARCH04                  Management Process              2
            Common Definitions
   Product Development Cycle: the period of time
    needed to complete the set of events that
    develops an idea into a quality product
   Process: the ordered set of events required to
    achieve a quality result and ensure robust,
    repeatable results
   Project: the organization of the team’s
    commitment to deliver a product
   Project Management: the control of team
    behaviors across the Product Development Cycle

                  Product Development Cycle and
11MARCH04          Project Management Process     3
Motivation
• Engineers should learn about today’s
  development practices

• An engineer’s skill set should
  parallel industry’s expectations

• Efficient individuals develop
  effective project management skills

11MARCH04   Product Development Cycle   4
             and Project Management
            Phases of the Product
             Development Cycle
   Phase 0 - Generate Idea
   Phase 1 - Plan
   Phase 2 - Develop
   Phase 3 - Validate
   Phase 4 - Qualify
   Phase 5 - Produce


                  Product Development Cycle and Project
11MARCH04                 Management Process              5
       Product Development Phases
Phase           0          1             2              3          4            5
           Sell Ideas     Plan        Develop        Validate    Qualify     Produce

 Goal     Generate      Develop     Advance         Proof of    Proof of     Robust
          many          Plan        idea to         specs       build        process
          ideas                     product
Process Develop         Plan the Engineer           Test        Build &      Release
          Ideas into    work for Functional         Proto       Test Pilot   Product
          Proposal      the Team Models             units       units        to Sell
 Main Initial           Gantt       Working         Solid       Working      Quality
Artifact Project        Chart       Modules &       System      Product      Product
          Summary                   Prototypes      Proto
Owner Project      Core                    Extended or Core Team Member
          Champion Team

                           Product Development Cycle and
   11MARCH04                Project Management Process                          6
     Project Management Process Steps
1.    Present an idea
2.    Plan the work
3.    Work the plan
4.    Learn from experiences




                  Product Development Cycle and Project
11MARCH04                 Management Process              7
       Process–Phase Relationship
Project Phase 0 Phase 1       Phase 2 Phase 3        Phase 4 Phase 5
Mgmt    Ideas   Plan          Develop Validate       Qualify Produce
Process
Steps
   1    Develop
        Ideas
   2             Plan the
                 work
   3                                        Work the Plan
   4          Learn from positive and negative events


                     Product Development Cycle and
  11MARCH04           Project Management Process                       8
Process Step 1. Present an Idea
Phase 0
• Collect ideas
• Consider customers
• Know stakeholders
• Write proposal (Initial Project Summary)

            QUICK




                    Product Development Cycle and
11MARCH04            Project Management Process     9
Ideas come from Many Sources
    •    Customer wants
    •    Customer needs
    •    Competitor products
    •    Competitor plans
    •    Marketing/sales logs
    •    Organizational strategies
    •    Society attitudes and opinions

                     Product Development Cycle and
STEP 1                Project Management Process     10
Consider All Customers

• External customers buy products that
  provide the lifeblood for the organization
• Internal customers have objectives linked
  to products that meet organizational goals
• Business partners help develop products
  to further everyone’s organizational goals
• Carefully consider each customer need
               Product Development Cycle and
STEP 1          Project Management Process     11
Know all Stakeholder Agendas

• Understand all external customer plans
• Check alignment of the idea with the
  current organizational strategies
• Solicit input from all internal customers
  and provide continuous feedback
• Uncover any hidden agendas through
  open conversations and discussions

                Product Development Cycle and
STEP 1           Project Management Process     12
         Develop the Initial Project
             Summary (IPS)
   Goal
   Product Roadmap                    Quick
   Key Selling Points
   Key Customers
   Proposed Team
   Business Case
   Recommendation to decision-makers
                 Product Development Cycle and
STEP 1            Project Management Process     13
Process Step 2. Plan the work
Phase 1
   Incorporate new organizational input
   Select the team
   Identify tasks
   Link deliverables to milestones
   Anticipate showstoppers
   Define tradeoffs
   Freeze the plan

               Product Development Cycle and Project
11MARCH04              Management Process              14
          Consider new input
   Decision-makers typically set direction for
   the project at the Phase 0 exit review
   (quality, performance, schedule and cost)
   Meld those inputs into the IPS as you
   develop the project plan
   Oversight or ignoring organizational
   direction can be costly down the road


                Product Development Cycle and Project
STEP 2                  Management Process              15
            Select the teams
   The core team may                     CORE TEAM
   include 8 members                       –   Research
   The extended team                       –   Quality
   contains as many                        –   Hardware
   members as needed                       –   Software
   to complete the work                    –   Mechanical
   – BUT time, humans                      –   Manufacturing
   and money are never                     –   Marketing/Sales
   infinite resources                      –   Finance


                Product Development Cycle and Project
STEP 2                  Management Process                       16
           Identify the tasks
   Break down the work into tasks for each
   project phase
   Assign owners
   Assign proposed due dates
   Set milestones and review dates
   Iterate to a potential plan


               Product Development Cycle and Project
STEP 2                 Management Process              17
                Link deliverables
   Match deliverables to milestones by phase.
   Plan for deliverables that are not tied to key
   milestones. What are some examples of key
   deliverables?
     –   New parts or components
     –   Module prototypes
     –   System prototypes
     –   Marketing collateral
     –   New test equipment and rework systems
     –   New manufacturing equipment or machines
                     Product Development Cycle and Project
STEP 2                       Management Process              18
            Define tradeoffs
   Showstoppers need defined before
   finalizing the plan
   Establish tradeoffs to give the team clear
   direction should known risks develop
   This task avoids wasted time later in the
   project. It shows the decision-makers a
   team’s due diligence to project success


                Product Development Cycle and Project
STEP 2                  Management Process              19
              Freeze the plan
   Establish reporting structure
   Define project metrics - QPSC
   Set firm values
     – Phase Schedules
     – Cost
     – Qualification date
     – Production date
     Recommend a final plan for approval
                 Product Development Cycle and Project
STEP 2                   Management Process              20
         Process Step 3. Work the plan
         Phases2-5
• The team must report on progress and address
  any issues as the project unfolds. The concepts
  for Work the Plan include:
     –   Commit and deliver to plan
     –   Monitor and report metrics with data
     –   Discuss obstacles and engage stakeholders
     –   Communicate change
     –   Recommit and deliver to change

                       Product Development Cycle and Project
11MARCH04                       Management Process             21
          Commit and Deliver
• “Can do” attitudes ensure project success



• Cohesive teams produce a synergy




                 Product Development Cycle and Project
STEP 3                    Management Process             22
            Report routinely
• Report project progress using data
• Communicate project status to all decision-
  makers and stakeholders with Quality,
  Performance, Cost and Schedule metrics
• Suggest recommendations when negative data
  identifies a need for change. Never report a
  problem without a recommended solution


                 Product Development Cycle and Project
STEP 3                    Management Process             23
Date: 11MAR04                       Status Report: 04-123                           Project Manager: Carson
GREEN                                                                                   Year-to-Date Project Figures

 RED            Quality                                  Project Start Date:10DEC04
                Performance                              Current Phase: Validation
                Schedule                                 Original End Date: 2APR04
                                                         Current End Date: 27APR04 5MAY04
                Cost
Project Budget: $_____        Upcoming Activities                                                                        Start Date
                              UACT 1
% Under Budget _____          UACT 2
                              UACT n
Expected $$ Overrun ___

% Over Budget   _____         Completed Activities                                                                     Completion Date
                              CACT 1
                              CACT 2
                              CACT n


Team Member         Summary of current week’s activities                                                               Due Date   Status

Andersen            Finalized the test fixtures for Proto3A                                                            20MAR04        Green
                    Modified the test code for UL testing platform                                                     24MAR04        Green

Zeller              Modified test fixtures for Proto4A                                                                 15MAR04        Green
                    Build self locking fixturing for Mfg Qualification tests                                           10MAR04        RED

Issue               Summary                                                    Action                                   Owner     Due Date

Schedule            Beryllium Copper late in arriving – due 12MAR              Will work OT on 13-14MAR                HILL       15MAR

Comments:           Low risk item: Mfg Engr has high confidence that Production tests will still meet schedule




         WEEKLY STATUS                                 Product Development Cycle and                                                     24
         REPORT                                         Project Management Process
         Discuss obstacles with
             stakeholders
• Discuss the effects of any obstacle with every
  stakeholder and ensure understanding
• Engage all stakeholders to meet each one’s
  needs. Over-communicate to ensure
  concurrence with change plans
• Submit recommendations to decision-makers
  and stakeholders. Welcome comments and
  feedback on any change plans
                  Product Development Cycle and Project
STEP 3                     Management Process             25
                     Cost of Changes
    Cost

1,000,000                                                                     $1,000,000
 900,000
 800,000
 700,000
 600,000
 500,000                                                           $500,000
 400,000
 300,000
                                                  $250,000
 200,000
 100,000
                                $50,000
       0        $500    $5,000
            Phase 0 Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


                           Product Development Cycle and Project
  HYPOTHETICAL                      Management Process                                     26
         Communicate change
             Never surprise anyone
• Over-communicate when change happens
• Ensure all decision-makers and stakeholders
  agree with any new tasks or plan changes




                 Product Development Cycle and Project
STEP 3                    Management Process             27
         Recommit and Deliver
• Change plans get the scrutiny of many

• Recognize there may be lots of emotion around
  any change in plans. It’s the team’s
  responsibility to plan accordingly

• Emphasize commitment and delivery to the
  change plan. It may be more important than
  achieving the original plan.
                 Product Development Cycle and Project
STEP 3                    Management Process             28
Process Step 4. Learn from experience
Phases 0-5
 Professionals use well-documented
  events to reinforce good behaviors
  and discourage bad ones.
 Continuous improvement discipline

  demands everyone to learn from
  past experiences – shed the bad and
  share the good.


             Product Development Cycle and
11MARCH04     Project Management Process     29
         Learn from experience
 Document events
 Train the positive

 Toss the negative

 Teach your world




              Product Development Cycle and
STEP 4         Project Management Process     30
           Document events

   Every project experiences both
    positive and negative events




   Record all events using accurate data

               Product Development Cycle and
STEP 4          Project Management Process     31
           Toss the negative
   Every event during a project is an
    opportunity for improvement.

   Eliminate these events from practice
    by modifying processes and work
    instructions to prevent recurrence.

   Live the NMI discipline
                Product Development Cycle and
STEP 4           Project Management Process     32
             NMI Discipline
   NameIt: If a process is not defined
    the you do NOT know what to do

   MeasureIt: You cannot measure a
    process unless you have defined it

   ImproveIt: A process cannot be
    improved unless you can measure it

               Product Development Cycle and
STEP 4          Project Management Process     33
           Train the positive
   Every event during a project is an
    opportunity for improvement.

   Incorporate these events into practice
    by modifying processes and work
    instructions to ensure recurrence.

   Live the NMI discipline

                Product Development Cycle and
STEP 4           Project Management Process     34
         Teach your organization
   Both positive and negative
    experiences provide valuable insight
    to others.


   Proactively share the “Lessons
    Learned” across the organization.
    Educate others of possible benefits in
    other areas of the organization.
                Product Development Cycle and
STEP 4           Project Management Process     35
                       Conclusions
Process Phase 0     Phase 1     Phase 2 Phase 3         Phase 4   Phase 5
Steps   Ideas       Plan        Develop Validate        Qualify   Produce

   1     Develop
         Ideas
   2                Plan the
                    work
   3
                                                           Work the Plan

   4              Learn from positive and negative events



                        Product Development Cycle and
  11MARCH04              Project Management Process                         36

				
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