7 Habits of Highly Effec3ve Product Development
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1 7 Habits of Highly Effec3ve Product Development September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 1
2 John Lenss John has over 18 years of experience in performing HALT. He has produced excellent results for many firms in the Twin ci3es area and around the United States. John currently works at 3M in the Personal Safety Division. He was the General Manager for Time Compression Labs, a HALT tes3ng facility in St. Louis Park, MN, un3l Gregg Hobbs premature death in July John has authored over 100 papers and been a presenter at events such as the American Society for Quality s Annual Conference, the Minnesota Reliability Consor3um, the Minnesota Quality Conference and the Accelerated Reliability Technology Symposium, to name just a few. This presenta3on and the data herein are from John s career and any specific companies men3oned have given John permission to tell this story. September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 2
3 Presenta3on Outline Things learned from working with over a dozen companies and performing hundreds of product HALTs. What are the 7 Habits? A Typical Product Development Process A Case Study September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 3
4 The Seven Habits are: 1. Concurrent Engineering with Mul3func3onal Teams 2. Product Robustness Must Be Put in at the Design Stage 3. Change the Designer s Mentality, to see Breaking Products as a Good Thing 4. HALT on the Prototype 5. FMECA is Needed to Disseminate Engineering s Knowledge to the rest of the Organiza3on 6. HALT on the Final solu3on 7. Know When the Project is Done and Celebrate September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 4
5 Phases of Product Development Ini3al Concept Phase System Design Phase Implementa3on Phase Product Acceptance Phase Manufacturing/Warranty Phase September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 5
6 Ini3al Concept Phase Inves3gate Market Needs, Poten3al and Technology Assess Program Viability Plan System Design Phase September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 6
7 System Design Phase Team Is Formed, Ini3al Timelines and Budgets are established by the team Define and Agree on Customer Requirements Define and Agree on the Solu3on Plan the rest of the program Design Verifica3on Tes3ng Prototyping of New Technologies/Processes Developmental HALT on prototypes September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 7
8 Implementa3on Phase Design, Test, and Produce the Final Solu3on System Verifica3on Tes3ng FMECA Agency Tes3ng Developmental HALT on Final Solu3on Run Safety of HASS September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 8
9 Product Acceptance Phase Test and Cer3fy that the solu3on works in the customer environment Beta Test Launch the product September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 9
10 Manufacturing/Warranty Phase Support the Program Warranty Iden3fy Process Improvements Rerun Safety of HASS If there are design changes/addi3ons, then a re- HALT must be done September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 10
11 Accelerated vs. Classical Product Development ID Task Name 1 ACCELERATED PROCESS 2 Specification from Customer 3 Engineering response to the specification 4 Initial Hardware design 5 Initial Software design 6 1st prototype 7 HALT 8 2nd prototype 9 Design Verification Test / Life Test 10 Manufacturing Process Development 11 Hardware Design Complete 12 Software Coding Complete 13 System Verification Test 14 Agency Testing Product Release 17 Manufacturing Building Product 18 FMECA Complete 19 First Product Warranty Phase 20 First product wearout CLASSICAL PROCESS 23 Specification from Customer 24 Engineering response to the specification 25 Initial Hardware design 26 Initial Software design 27 1st prototype 28 Reliability Calculation 29 2nd prototype 30 Design Verification Test / Life Test 31 Manufacturing Process Development 32 Hardware Design Complete 33 FMEA Complete 34 Software Coding Complete 35 System Verification Test 36 Agency Testing 37 Product Release 38 Manufacturing Building Product 39 First Product Warranty Phase 40 First product wearout quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb 3/29 3/29 6/21 6/21 1/3 10/3 1/2 1/23 1/23 12/4 September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 11
12 e N - Counter 4000 TM Transac3on Terminal Case Study September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 12
13 Direc3on for this new product 1. Make e N - Counter 4000 THE most reliable product on the market 2. Come up with a plan to implement quality/ reliability improvements in all legacy products September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 13
14 Gejng Buy- In from the Developers I provided the training for our development team on why we should so a HALT and what we would gain by performing HALT, as opposed to the other tes3ng we dad planned. September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 14
15 e N - Counter 4000 HALT Timeline March first HALT seminar June - Developmental HALT on e N - Counter 4000 ini3al release product June - HALT results discussed with Mfg, Service, and Design Engineering July Legacy products - Transac3on Terminals - Developmental HALTs October - Printer Developmental HALT September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 15
16 Legacy Products HALT September - e N - Counter 4000 Released to the Public November - Reliability Engineering and Management Ins3tute at U of Arizona, Tucson September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 16
17 Addi3onal Timeline Items August - Developmental HALT on e N - Counter 4000 block release (ASIC Version of Product) December - FMECA March Purchased a HALT chamber, 2 years amer first learning about HALT Used for e N - Counter 4000 HASS Used by other divisions for their own HALTs September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 17
18 Sales Pitch story Compe33on Gets Blindsided by Our Customer September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 18
19 The Seven Habits are: 1. Concurrent Engineering with Mul3func3onal Teams 2. Product Robustness Must Be Put in at the Design Stage 3. Change the Designer s Mentality, to see Breaking Products as a Good Thing 4. HALT on the Prototype 5. FMECA is Needed to Disseminate Engineering s Knowledge to the rest of the Organiza3on 6. HALT on the Final solu3on 7. Know When the Project is Done and Celebrate September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 19
20 Accelerated vs. Classical Product Development ID Task Name 1 ACCELERATED PROCESS 2 Specification from Customer 3 Engineering response to the specification 4 Initial Hardware design 5 Initial Software design 6 1st prototype 7 HALT 8 2nd prototype 9 Design Verification Test / Life Test 10 Manufacturing Process Development 11 Hardware Design Complete 12 Software Coding Complete 13 System Verification Test 14 Agency Testing Product Release 17 Manufacturing Building Product 18 FMECA Complete 19 First Product Warranty Phase 20 First product wearout CLASSICAL PROCESS 23 Specification from Customer 24 Engineering response to the specification 25 Initial Hardware design 26 Initial Software design 27 1st prototype 28 Reliability Calculation 29 2nd prototype 30 Design Verification Test / Life Test 31 Manufacturing Process Development 32 Hardware Design Complete 33 FMEA Complete 34 Software Coding Complete 35 System Verification Test 36 Agency Testing 37 Product Release 38 Manufacturing Building Product 39 First Product Warranty Phase 40 First product wearout quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter 2nd Quarter 3rd Quarter 4th Quarter 1st Quarter May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb 3/29 3/29 6/21 6/21 1/3 10/3 1/2 1/23 1/23 12/4 September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 20
21 Resources for papers and chambers for papers hnp:// tes3ng/ failure- mode- verifica3on- fmvt/ - FMVT for chambers papers and chambers test services September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 21
22 John Lenss Ques3ons: 3M Personal Safety Division September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 22
23 September 5, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 23
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