Product Design and Development Process

For timely and successful  product delivery we can categorize complete product design and development process in various stages like : Product Initialization, Preliminary Design, Detailed Design, Product Design, Validation & Certification, Qualification phase, Production Pilot Run, Final production.

Project Initialization

Objectives

Kick off meetings with team leads.

Activities & Deliverable

  1. Identify resources necessary to start project development.
  2. Customer requirements capture.
  3. Initial level project cost estimate.

Project Initialization : Project Requirements Capture

Objectives

Analyse customer requirements, define project objectives and resources.

Activities & Deliverable

  1. Capture Project Requirements : Requirements Conformity Matrix
  2. Project Risks Identification
  3. Team Identification
  4. Project Plan & Schedule
  5. Budget Estimation

Preliminary Design

Objectives

Product architecture design and Identify design, manufacturing and purchase risks.

Activities & Deliverable

  1. Product functional specification
  2. Requirement trace-ability matrix
  3. Product Preliminary and Architecture Design : Preliminary Design Document
  4. Preliminary manufacturing flow chart
  5. Environmental qualification tests plan
  6. Robustness tests plan
  7. Risks Mitigation Plan

Detailed Design : Phase 1

Objectives

Define Product/Process Detailed Design (simulation, mock-up, calculation)

Activities & Deliverable

  1. Product Design Reliability calculations using simulation and manual calculations.
  2. Submit design, manufacturing and testing Documents with proof of concept
  3. Sub-assembly design and justification of design choices
  4. Value Analysis
  5. A Class Component selection and justify component selection
  6. Develop Mock-up
  7. Define verification & validation Tests
  8. Define environmental qualification and robustness tests procedure
  9. Define the tests bench
  10. Design Review : All Design Documents, Proof of Concept, Simulation studies results need to be verified by senior team member and independent review need to be done.

Detailed Design : Phase 2

Objectives

Product/Process Theory Detailed Design

Activities & Deliverable

  1. Finalization of Cad Models, Engineering Drawings and Materials
  2. Tolerance Stack-up Analysis
  3. Finalization of Vendors
  4. Design Review : Complete design need to be reviewed by other independent team.

Product Verification

Objectives

Validate all Element & interfaces independently before Product integration

Activities & Deliverable

  1. Prototype Manufacturing
  2. Initial Samples Validation
  3. Assembly Process Verification

Product Validation

Objectives

Functional validation tests and pre-qualification test

Activities & Deliverable

  1. Functional Validation Tests
  2. Pre-Certification Test
  3. Robustness tests
  4. Manufacturing documentation

Qualification Phase

Objectives

To make sure product and manufacturing process are in accordance with the requirements

Activities & Deliverable

  1. Initial manufacturing Pilot Run
  2. Functional Validation and certification tests
  3. Product process Audit
  4. PPAP, Design FMEA, Process FMEA, flow chart, capabilities, control plan etc.
  5. Manufacturing Process Validation
  6. Manufacturing Documents
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