While working in a mid scale company that specializes in manufacturing Hydraulic tanks, fuel tanks, hydraulic jacks, pumps, cylinders and chassis parts , i got exposed to new product development in the fabrication department. Here I will explain the process flow of how a new product was developed in the company.
The steps involved in new product development were:-
1) Receipt of drawing from customer
2) Cost analysis and feasibility analysis
3) Time plan and RTS (Review of technical specifications)
4) Fixture design
5) Prototype production
6) Initial sample approval
1) Receipt of drawing from the customer:-
Since the product design was made at the customer end we received the drawings from the customer with complete product specification and the standards to be followed. These drawings would be sent to the marketing department.
2) Cost Analysis and Feasibility analysis:-
Marketing department will carry out the cost analysis of the product which includes detailed cost calculation each and every process involved in making the product.
And then passes on the drawing to the new product development team who carry out the feasibility analysis which involves checking if the project is feasible in terms of technical specification and also the investment that needs to be made i.e. to analyze if we have the technical capability to meet the design requirements.
3) Time plan and RTS:-
The next step would be to make a complete time plan of the project with the customer from the procurement stage to the point where the product will be delivered to the customer which includes a detailed time plan of the each and every process involved in the project. Next is a review of technical specifications which includes going through the drawing in complete detail and checking for the corresponding standards for each part and process. I was involved in both these processes.
This also includes a meeting with the purchase and planning department to decide which parts have to be outsourced and which parts have to be produced in-house.
4) Fixture design:-
Design of fixture is carried out by design department with inputs from the development team who provide their practical inputs of the requirements that they have. Design of the fixture parts is a critical part of the development process.
5) Prototype production:-
After the fixture design is done, the next step involves the development of the prototype. Once the prototype is developed and any deviation in the product from drawing specification is recorded and correction is made in the fixture and also the process to meet the customer specification and a prototype which meets the customer specification is done it is delivered to the customer, and the product is checked for fitment at customer end. If there is no deviation in the fitment the prototype is accepted.
6) Initial sample approval:-
After the prototype is approved, initial sample parts are produced and sent to the customer and initial sample parts approval is taken from the customer.
After initial sample approval, the project has to be handed over for regular production but before that all the processes should be documented and handed over to the production department which helps in establishing a standard process. This is known as PPAP (Production part approval process), the documents made are:-
- Design records
- Control plan
- Process flow chart
- FMEA (Failure mode and effective analysis)
- Quality plan
- Material performance tests
- PSW (Part submission Warrant) etc
This was a brief description of the process flow in new product development in a manufacturing firm.
– Tejaswi (Batch 2009-11)