INTRODUCTION TO PRODUCT AND PROCESS DEVELOPMENT

STUCTURE OF THE PRESENTATION

CONCEPTS : PRODUCT , PROCESS, INTEGRATED PRODUCT, INTEGRATED PRODUCT AND PROCESSES

WHY AND WHEN: INTEGRATED PRODUCT AND PROCESS DEVELOPMENT

BENEFITS OF IPPD WHAT IS IPPD : DoDs DEFINITION OF IPPD 5 PRINCIPLES OF IPPD THE TEN TENETS OF IPPD GENERAL PNICIPLES OF IPPD INTEGRATED PRODUCT TEAM

KEY CONCEPTS OF IPT

HOW IPPD : IMPLEMENTING IPPD TOOLS OF IPPD CONCLUSION

PRODUCT AND PROCESS

PRODUCT: -IS WHAT IS DELIVERED TO THE CUSTOMER e.g.

HARDWARE, SOFRTWARE, SERVICES, TRAINING

-IT IS THE PHYSICAL HIERARCHY OF THE SYSTEM OR PHYSICAL ARCHITECTURE - IS ALWAYS ACCOMPANIED BY A SPECIFICATION PROCESS : - MAKES THE PRODUCT POSSIBLE - IT IS AN ACTIVITY OR GROUP OF ACTIVITIES THAT TAKES AN INPUT ADDS VALUE TO IT TO GET AN OUTPUT FOR AN INTERNAL OR EXTERNAL CUSTOMER e.g. DESIGN, MANUFACTURING, TEST& EVALUATION, LOGISTICS

3 TYPES OF PROCESSES
TOP LEVEL : FUNCTIONAL. OVERARCHING PROCESS SUCH AS SYTEMS ENGINEERING, TEST AND EVALUATION DEVELOPMENT PROCESSES : ARE PROCESSES THAT FACILITATE MAKING OF A PRODUCT. THESE PROCESSES ARE NOT DELIVERED TO THE CUSTOMERINCLUDE INTEGRATION, PRODUCTION, COMPUTER SUPPORT, MODELLING AND SIMULATION DELIVERABLE PROCESSES : CAN BE THE PRODUCT OR PROCESS TO SUPPORT THE PRODUCT- INCLUDES SUPPORT, TRAINING, MAINTENANCE

INTEGRATED PRODUCT
REALISES THAT: -THE WHOLE IS MORE THAN THE SUM OF THE PARTS -WHAT IS BEST FOR THE SUBSYSTEM (OR COMPONENTS) IS NOT NECESSARILY THE BEST

FOR OVERALL SYSTEM OR VICE-VERSA

INTEGRATED PRODUCT AND PROCESS

BECAUSE OF THE LIMITED TIME AVAILABLE TO BRING A PRODUCT TO THE MARKET MUCH OF THE PLANNING AND DEVELOPMENT STAGES DOWNSTREAM FROM DESIGN ( MANUFACTURING, TESTING, DISTRIBUTION etc. ) OCCURS PRIOR TO THE COMPLETION OF FINAL ENGINEERING DRAWINGS AND SPECIFICATION. THIS RESULTS IN THE CONCURRENT DEVELOPMENT OF THE PRODUCT AND THE PROCESS

COMPETITIVENESS
THE THREE ELEMENTS OF COMPETITIVENESS ARE: TIMELINESS: CAN THE PRODUCT BE DELIVERED JUST IN TIME DEMANDED BY THE CUSTOMER QUALITY: WILL THE PRODUCT WORK AS WELL AS INTENDED AFFORDABILITY: WILL THE CUSTOMERS WISH TO BUY THE PRODUCT TO GAIN COMPETITIVE ADVANTAGE WE MUST DESIGN FOR VALUE

BENEFITS OF IPPD
REDUCED TIME TO FIELD SYSTEMS REDUCED SYSTEM COST

IMPROVED QUALITY
PROGRAMMES THAT ARE EASIER TO MANAGE

DESIGN CHANGES

A GENERIC IPPD
ITERATIVE PROCESS

DEFINITION OF IPPD
DODS DEFINITION A MANAGEMENT PROCESS THAT INTEGRATES ALL ACTIVITIES FROM CONCEPT THROUGH PRODUCTION, FIELD SUPPORT USING A MULTIFUNCTIONAL TEAM TO SIMULTANEOUSLY OPTIMISE THE PRODUCT AND ITS MANUFACTURING AND SUSTAINMENT PROCESS TO MEET COST AND PERFORMANCE OBJECTIVES

IPPD
IPPD IS SOMETIMES CALLED IPD IPPD IS A MANAGEMENT APPROACH IPPD IS NOT A SET OF STEPS TO BE FOLLOWED IPPD HAS NO SINGLE IMPLEMENTATION STRATEGY SOLUTION OR

IPPD HAS ITS ROOTS IN INTEGRATED DESIGN AND PRODUCTION PRACTICE , CONCURRENT ENGINEERING PRACTICE AND TOTAL QUALITY MANAGEMENT

IT IS PERFORMANCE DRIVEN NOT PROCESS DRIVEN

APPLICATION OF SYSTEMS ENGINEERING PROCESS IS FUNDAMENTAL TO IPPD

5 PRINCIPLES OF IPPD
5

STAKEHOLDER INVOLVEMENT AND CUSTOMER FOCUS CONCURRENT DEVELOPMENT OF PRODUCT AND PROCESSES EARLY AND CONTINUOUS LIFE CYCLE PLANNING PROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK MAXIMUM FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES

THE TEN TENETS OF IPPD

CUSTOMER FOCUS CONCURRENT DEVELOPMENT OF PRODUCTS AND PROCESSES EARLY AND CONTINUOUS LIFE CYCLE PLANNING

MAXIMISE FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES

ENCOURAGE ROBUST DESIGN AND IMPROVED PROCESS CAPABILITY EVENT DRIVEN SCHEDULING MULTIDISCIPLINARY TEAM WORK

THE TEN TENETS OF IPPD

EMPOWERMENT SEAMLESS MANAGEMENT TOOLS PROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK

CUSTOMER REQUIREMENTS

Mission Need Statement Operational Requirement Document

Translate Customer Requirement Level 0 system specification document

ESTABLISH AN INTGD. MGMT. FRAMEWORK

Outline programme Product broken down to 2 levels below System level

OUTLINING THE PROGRAMME

Specification tree that follows Product BreakOUT

Prepare WBS WBS doc

Prepare integrated Master schedule define TPMs IMS doc. TPMs

Prepare Integrated Master Plan Event driven IMP doc

Define Core Prepare SOWs Program Key SOW Doc Events Planning the Program Track and execute program

Allocate Resources Organisation (People) Funds Time

General Principles of IPPD

KEY FEATURES OF IPPD

PRODUCT ORIENTATION: PRODUCTS DICTATE THE ULTIMATE SUCCESS OF THE ORGANISATION IN THE EYES OF THE CUSTOMER CROSS FUNCTIONAL TEAMING: EFFECTIVE TEAMING BETWEEN FUNCTIONAL REPS. INTELLIGENT DECISIONS BASED ON COMBINED EFFORT OF ENGG. PRODN. LOGISTICS, PGMME. MGMT.,CONTRACTING, FINANCIAL MGMT., SUSTAINMENT,OPS., & OTHER DISCIPLINES EMPOWERMENT: GIVE REQUISITE AUTHORITY AND ESPONSIBILITY

CONTD.

KEY FEATURES OF IPPD

UPFRONT PLANNING: DELIBERATE UPFRONT PLANNING EARLY IN THE PRODUCT LIFE CYCE. EVENT BASED PLANNING

IMPLEMENTING IPPD
CULTURAL CHANGE: INTEGRATED DECISION MAKING , EMPOWERMENT FRAMEWORK: IN NEW ACQUISITION THE FRAMEWORK IS ESTABLISHED IN THE RFP ITS IMPLEMENTATION IS PRODUCT AND PROCESS DEPENDENT

INTEGRATED PRODUCT TEAM

THE PROCESS SIDE OF THE EQUATION INCLUDES ALL THE INDIVIDUALS ADDING VALUE TO THE PRODUCT. THESE INDIVIDUALS ARE MULTIFUNCTIONAL IPTS

KEY CONCEPTS OF IPT

HIGH PREMIUM ON INFORMATION AND COMMUNICATION TEAM LEADERS ARE KEY

CHECKS AND BALANCES PROVIDED BY TECHNICAL CONSCIENCE

STRONG TEAM CULTURE

INDIVIDUALS EMPOWERED WITHIN CLEARLY DEFINED ROLES AND RESPONSIBILITIES

IPPD TOOLS
Information Technology and decision support Trade off studies and Prioritization Cost Performance trade offs Design for Manufacturing Prototyping Modeling Simulation and CAE/CAD/CAM Metrices (Measures of Success) Education and Training

ORGANISATION EVOLUTION
THE OLD WAYS MISSION TO MAXIMISE FINANCIAL PERFORMANCE
HIERARCHIAL AUTHORITARIAN STRUCTURE NARROWLY DEFINED INDIVIDUAL JOBS MANAGE PEOPLE TO MANAGE RESULTS

THE NEW WAYS MISSION OF TOTAL CUSTOMER SATISFACTION,CONTINUOUS IMPROVEMENT , LEARNING FLEXIBLE TEAM STRUCTURES WITH AUTHORITY CLOSEST TO WORK CAPABILITY INTEGRATED WORK TEAMS WITH BROAD SCOPE
MANAGE PROCESS TO MANAGE RESULTS RECRUIT PEOPLE WITH COMMITMENT TO MISSION, SKILLS AND KNOWLEDGE. PROVIDE TRAINING FOR PERSONAL GROWTH

RECRUIT PEOPLE WITH FUNCTIONAL EXPERTISE

SYSTEMANTICS
SYSTEMS IN GENERAL WORK POORLY OR NOT AT ALL (PRIMAL SCENERIO) NEW SYSTEMS GENERATE NEW PEOBLEMS ( THE FUNDAMENTAL THEOREM) BIG SYSTEMS EITHER WORK ON THEIR OWN OR THEY DONT. YOU CANT MAKE THEM ( BASIC AXIOM OF SYSTREMS FUNCTION) A SIMPLE SYSTEM , DESIGNED FROM SCRATCH, SOMETIMES WORKS A COMPLEX SYSTEM THAT WORKS IS INVARIABLYFOUND TO HAVE EVOLVED FROM A SIMPLE SYSTEM THAT WORKS

SYSTEMANTICS(CONTD.)
A COMPLEX SYSTEM DESIGNED FROM SCRATCH NEVER WORKS AND CANNOT BE MADE TO WORK. YOU HAVE TO START OVER , BEGINNING WITH A WORKING SIMPLE SYSTEM COMPLEX SYSTEMS ARE BEYOND HUMAN CAPACITY TO EVALUATE

VIRTUAL PROTOTYPING
BRINGS VISUAL SIMULATION TECHNOLOGY

TO PRODUCT DESIGN AND MANUFACTURING TEAMS PERMITS ASSEMBLY STUDIES FIND OPTIMUM ASSEMBLY AND DISASSEMBLY SEQUENCES, CLEARANCE BETWEEN PARTS AND REAL TIME INTERFERENCE CHECKS MAKES DIGITAL MOCK UP A REALITY CAN CHECK INTERFERENCES EVEN IN LOADED VIBRATING STRUCTURES. COULD BE USED TO PREDICT SHORTS IN ELECTRONIC PACKAGING

VIRTUAL PROTOTYPE
PREDICT AND PREVENT TRADITIONAL APPROACH TO DESIGN FIND & FIX

SITUATION OF AIRCRFT COMPANIES

TO COMPETE GLOBALLY AIRCRAFT COMPANIES MUST DEVELOP AT: HALF THE COST IN HALF THE TIME WITH HALF THE RESOURCES USED EARLIER

DRIVING FORCE- AFFORDABILITY

REDUCE COST WITHOUT COMPROMISING QUALITY

IPPD
IPPD EXPANDED ON CONCURRENT ENGINEERING

INCLUDING DEVELOPING ALL THE PROCESSES

PARELLEL WITH THE PRODUCT. MORE THAN THE PRODUCT AND PROCESS ENGINEERING FUNCTIONS IPPD ALSO INCLUDES ALL STAKEHOLDERS- THOSE NOT ONLY DEVELOPING THE PRODUCT BUT ALL

PRODUCT RELATED PROCESSESS SUCH AS TEST

AND EVALUATION , MANUFACTURING , SUPPORT OPERATIONS AND TRAINING AS WELL AS

BUISINESS PROCESSES