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New Product Introduction Process

Zenaca Consulting Revision 0

Amarpreet Singh Mar 27, 2024
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Agenda
• Purpose & Definition of NPI
• Objectives
• Importance of Toll Gate Process
• Toll Gate Process
• Details of Every Toll Gate Process

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Purpose

“ The purpose of this document is to provide guidelines

for defining New Product Introduction (NPI ) procedure
for an EMS or an OEM organisations dealing in PCBA
and Box build Assemblies.”
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Definition
In the context of EMS (Electronics Manufacturing Services), NPI refers to the process
of introducing a new product into the manufacturing environment

The introduction can be a product transfer from other factory or a complete launch
of a new product in the manufacturing environment.

It involves steps such as design and process validation, prototyping, testing, and
final verification of the product as per design specifications.

NPI ensures that the product is efficiently and effectively manufactured according to
specifications, meeting quality standards, and ready for mass production launch.
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Abbreviations
§ CFT – Cross Functional Team § DCM – Document control
§ PLM – Product Life Cycle management
Management
§ FAI – First article inspection
§ BOM – Bill of Materials
§ FMEA – Failure mode and effect
§ MES – Manufacturing Execution
analysis
System

§ MCL – Master Clarification List § RCA – Root cause and Analysis

§ DFM – Design for manufacturing § COC – Certificate of compliance

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NPI Objectives
P I Z Z A

Pass Qualification 100% On time Ability to ramp up

Zero Scrap Zero Escalation
First Time Delivery better than quote

• All the process • Samples must • Target Zero • No escalation • The processes used
during the NPI must
during the NPI be delivered to SCRAP during related to
be scalable.
needs to be customers on the NPI. All the technical,
defined in a time as per first processes commercials or • Once qualified, the

way that the product must be

commitment needs to be deliveries from
ramped up in
product must
defined end customers production
qualifies environment better
accordingly
without any than quotation

iterations assumptions

Credit : Flextronics Penang ( Formerly Solectron International ) NPI Process

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NPI Process
Every NPI is different from other considering the product complexity,
customer specifications, Quality and reliability requirement and ramp up
expectations.

A detailed toll gate process needs to be established and followed, so that

all the aspects on an NPI are well covered and executed keeping the NPI
deliverables in sight.

A formal sign off to be obtained from all the stake holders before moving
to the next step in the process.
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Importance of Toll Gate Process

Quality Assurance: Toll gates ensure that each phase of the NPI process
meets expected quality standards. By passing through toll gates, potential
issues and risks can be identified and addressed before progressing to the next
phase, thus maintaining product quality throughout the NPI process.

Risk Management: Toll gates help in assessing and mitigating risks associated
with introducing a new product. By evaluating key milestones and criteria at
each gate, organisations can identify and manage risks early on, reducing the
likelihood of costly errors or delays later in the process.
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Importance of Toll Gate Process

Decision Making: Toll gates facilitate decision-making by providing
structured review points where stakeholders can evaluate project
progress, make informed decisions, and determine whether to proceed,
pause, or halt the project based on the available data and analysis.

Timeline Management: Toll gates help in managing project timelines by

setting clear milestones and deadlines for each phase of the NPI process.
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Toll Gate Process

Toll Gate 1 Toll Gate 2 Toll Gate 3 Toll Gate 4 Toll Gate 5
( TG-1 ) ( TG-2 ) ( TG-3 ) ( TG-4 ) ( TG-5 )

• Formation of • Build readiness • Qualification • Pilot build as a • Production runs

CFT including (Proto) build confirmation till the product
• Project documentation, and sample run with achieve
handover from Tooling, submission to increased required quality
customers
BD/Sales team Materials, Line, sample size.
targets and
• RCA for any
to operations people etc. • Product moved
observations volumes.
team to production
from customers
on the samples

* Every toll gate have a formal signoff before moving to next stage

Credit : Flextronics Penang, Malaysia ( Formerly Solectron International ) NPI Process

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Toll Gate - 1
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TG-1

Project Hand
Kick Off TG-1
CFT Formation over to NPI
meeting Sign off
Team
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TG-1
The first step in the project is forming a team ( Cross Functional Team –
CFT ) from operations to execute the project. The team should have active
representation and participations from various functions like :

• Program Management • Test engineering

• Manufacturing Engineering • Purchase

• Quality • Material and production planning

• Production leader • NPI ( New Product Introduction )

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TG-1
A kick off meeting between sales/BD and operations team is organised to
handover all the project related information which is -

vFinal data pack from customer vPacking details

vQuotation & assumptions vLogistics and delivery information

vMCL ( Master Clarification List ) vDelivery expectations
vNRE Details (Non-recurring Expenses)
vQuality expectations
vTest matrix and methodology
vProject feasibility report
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TG-1
Toll gate 1 is signed off at the closure of kick off meeting.

All the documents are released in the PLM or DCM so that everyone in the
organisation refers to those details during the execution of the project.

Any deviation to the process or absence of certain documents is communicated

acknowledged and agreed by the team to process the proto build.

Any further changes to the data pack once released are executed using
engineering change note process.

Please reach out to us individually in case you need various formats used during the process
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Toll Gate - 2
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TG-2
In this phase all the internal preparations are done for executing a flawless
proto build.

The success of the NPI build reflects the details with which this toll gate is
executed in the organisation.

Customers are kept updated about the progress and any clarifications or
deviations are approved by customers if required.
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TG-2 Process

Build TG-2 Sign

Readiness off

1 2 3 4

TG -1 Sign Readiness
Off Review
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TG-2 Outcome
Method Machine

Process FMEA Machine capability study

Process flow and assembly work

SMT / Test Programs
instructions

Final packing and labels definition Offline programming instructions

Special process qualification Process and test tooling

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TG-2 Outcome
Manpower Materials

Material availability ( BOM and

Operator identification
consumables )

Supplier COC as per customer

Operator training and certifications
requirements

Availability / Allocation BOM Cost comparison with quote

DFM Analysis Tooling/ Jigs procurement

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TG-2 Outcome
Bill Of Materials Quality

BOM - Internal format CTQ Definition

Assembly matrix Control plan

Compliance matrix FAI - Customised components

MES Set up Line audit before the build

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TG-2
All the output of TG2 are recorded as per controlled checklists and
formats.

All the records are updated in DCM for future reference at the time of sign
off. The proto build can start only once TG-2 is signed off by the CFT.

Any deviation to the process needs to be formally approved as deviation

from the authorised persons in the organisation.
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Toll Gate - 3
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TG-3 Process

Proto Build TG-3 Sign off

1 2 3 4

FAI & Customer

TG -2 Sign Off
approvals
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TG-3
In this phase the actual build happens on the shop floor. All the processes are
executed as per the defined procedures in TG-2.

Observations, if any are recorded as part of the build summary.

The defects and any rework carried during the build are analysed and a detailed
RCA for every defect is defined and tracked for closure.

The FAI report is shared with customer for approvals along with samples.

TG-3 Is signed off after the formal approval from customer on FAI and samples
submitted.
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Toll Gate - 4
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TG-4 Process

TG-4 Sign
Pilot Build
off

1 2 3 4

TG -3 Sign Yield
Off Analysis
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TG-4
Once customer approval or feedback is received, the next phase is to have a
pre-production or pilot build referred as TG-4.

The purpose of this build is to simulate all the manufacturing environment

including the cycle time and process yield levels.

In certain cases, there might be more than one pilot build to achieve the yield
levels before transferring to production.

If required, duplicate tooling needs to be procured for mass production after the
required modifications.
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Toll Gate - 5
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TG-5 Process

Mass Production TG-5 Sign off

1 2 3 4

Ramp Up (Quality
TG -4 Sign Off
and Quantity)
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TG-5
The product is moved to mass production after successful completion of pilot
build or multiple builds.

In TG-5 the product is monitored by the NPI team, till it reaches the expected
quality levels and volumes as per customer requirements.

Quote Vs Actual analysis is performed and reported to finance for approvals.

Any corrections in the customer quotation happens in this phase of the project.

Once TG-5 Is signed off, the sustaining team takes over the project and runs it
till end of life of the project.
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NPI Review
A Daily meeting is required to review the toll gate status of each build
which is on-going in the organisation.

It is recommended to have a visual dashboard in NPI area, where the

progress of each NPI build is displayed and reviewed every day.

NPI Objectives ( P1ZZA ) to be measured for each build and product

which is launched in production. Any feedback from P1ZZA score card to
be looped back to the NPI process for future improvements.
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Do you have more questions on topic ?

Please reach me at
Email : [email protected]
Contact : +91 96866 83783
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Thank You
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