Design Phased Development
Phased Development Step Process for
Development of new products requires that an orderly
set of steps or "phases" be followed by the engineering,
marketing, and manufacturing teams to avoid costly mistakes.
Industry experience has demonstrated that it may cost three
to ten times more to correct oversights, which should have
been accomplished in a preceding phase.
A summary of the primary phases, which have come to be generally
accepted as an efficient development process, follows.
Emphasis is on the engineering design aspects, and they apply
in principle to all company divisions.
• Examine marketplace requirements
/ client's business model.
• Generate "blue sky"
• Identify key team members,
both for us and the client.
• Create development
budget, schedule, milestones plan.
• Initiate ID exploration.
• Document concept, feasibility,
costs and specifications.
• Define resource management.
• Develop engineering
and agency requirements.
• Develop appearance
• Qualify vendor list.
• Create assembly documentation.
• Test functional prototypes.
• Release detailed CAD,
• Review COGS with manufacturing
• Complete engineering
analysis / design verification testing.
• Initiate agency submissions.
• Identify service needs
• Design and quality
• Support production
• Evaluate manufacturing
• Execute engineering
/ manufacturing change orders.
• Benchmark and refine
0: Introductory Phase
Initial product definition and "getting to know
each other" phase. This phase also highlights major work
tasks to be done.
Phase 1: Concept & Feasibility Study
A product is broadly defined based upon a perceived
market need. Marketing and Engineering jointly determine market
and technical feasibility. Engineering may model high-risk
subsystems to build needed technical confidence.They then
issue a summary report of findings and a beginning product
Deliverable: A technical study report is
created which typically summarizes study findings and attempts
to define a preliminary product specification with sketches,
Phase 2: First Prototype
A project team is selected, a kick-off meeting is
held and product spec.'s are further defined along with regulatory
requirements (U/L, IEC, EU, FDA, etc.) A "breadboard"
model is designed and built to assure design bugs are corrected
before commitment to tooling. Documentation is usually informal
during this phase. Engineering and marketing meetings are
held as needed to formalize a first working product specification.
Industry experience has shown that many clients push to bypass
this phase and rush to get the product tooled prematurely.
This has proven to be a costly mistake !
Deliverable: A breadboard working model,
minimum documentation, and more complete specification, and
a summary report.
Phase 3: Prototypes Production
This Phase requires funding for parts, build, and
tooling (plastic molds, PCB's, panel graphics, initial regulatory
testing, etc.) for a small number of the product. The product
team is expanded to include manufacturing personnel. The team
creates a more detailed specification (and marketing, financial
plans., etc.) Engineering then designs, documents, tools and
procures sufficient parts to manufacture and test a small
evaluation build (2 to 5 typical).
These prototypes are used for regulatory testing, marketing
Deliverable: Completed primary manufacturing
documentation and 2 to 5 working prototypes. Initial regulatory
agency test results and needed product changes are also completed,
Phase 4: Pilot Production
The first fully controlled and documented products
are made for initial sales during this phase. This is a vital
phase for cooperation between engineering and the manufacturing
Typically ten to twenty products are made with responsibility
gradually shifting from engineering to full manufacturing
operations as engineering completes and debugs both the product
and its documentation.
Deliverable: Complete manufacturing documentation,
fully trained manufacturing personnel. and a modest quantity
of delivered product.
Phase 5: Early Production
During this phase, manufacturing personnel largely
handle the product's build and support. The documentation
is placed under formal control (ECN's, DCO's, etc.) and engineering
provides sign-off and review of any needed changes until the
product is technically stable.
you need more information or consulting services for a project's
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