Phase Gate process, S5 and lean manufacturing to produce world class equipment with outstanding profit

1. Phase-Gate, 5S and Lean Production
Principles
to
Manufacture Superior Products
and
Maximize Profit

2. Product Development and Production Process
Gate 1 Gate 2 Gate 3 Gate 4
Invention & Technology Product Verification & Continuously
Innovation Development Design Optimization Monitoring of
Phase Phase Phase Phase Production
Phase 1 Phase 2 Phase 3 Phase 4 Production
What is it? Make it work / Excellent Product Make it fail /
Make it fail Make it work
Customer & strategic Clarify customer & Customer needs → Capabilities & Continuous
Requirements . business needs excellent product Certifications improvement and
requirements valuation of production
Alternative Develop the best Product Attributes & QA robustness Continuous Customer
technology technical solution performace examination redesign Care
methodes requirements
Define investment Understand / Prevent System Integration CE, OSHA, TUV & outdated
opportunities Errors other required
conformity
Manufacturing Adapt manufacturing Launch readiness product End of Life
strategies operations and
service strategies
Alpha Test Beta Test
Voice of the Customer
Leadership Principles: superiority, robustness, simultaneous engineering, planning and continuous improvement.

3. Product Development Process - Gate Review Questions
GATE 1 GATE 2 GATE 3 GATE 4
Invent & Innovate Technology Development Product Development/ Verify / Optimize
Manufacturing
Product Management What is the idea & why What is the idea & why What is the product What is the final product
(statement of product)? (statement of product)? specification? specification?
Regulatory / Patent Issues? Regulatory / Patent Issues? How do we compare to the •What are the Life Cycle
competition? implications?
Sales / Marketing What is the selling price? What is the selling price? What is the selling price? What is the selling price?
How many will be sold How many will be sold How many will be sold How many will be sold
annually? annually? annually? annually?
What are the selling List of sales spreadsheets,
strategies? literature, personnel trained &
advertising plan.
Engineering /Software What are the alternative What are the performance What are the Alpha Test What are the Beta Test
technologies? results? results (performance & results?
What is the estimated What are the failure modes? failure)? What are CE/ OSHA Compliance
development cost, unit costs What are the estimated Design specification. results?
and ROI for the recommended development cost, unit costs What are the unit costs & Show exploded drawings with
approach? & ROI? actual ROI? part numbers.
What is the anticipated What is the anticipated What is the anticipated What is the anticipated
schedule and resource list for schedule and resource list for schedule and resource list for schedule and resource list for
Phase 2? Phase 3? Phase 4? Phase 5?
How to optimize the build How to optimize the build
process? process?
Manufacturing Overview Assessment What are the manufacturing What is the manufacturing What is the unit cost based
strategies (technical, plan and status (technical, upon the BOM?
personnel & external personnel & external List the build procedures
resources)? resources)? Improve the build procedures
Customer Service Overview Assessment Overview Assessment What are the service Who has been trained on the
strategies (personnel, training product?
& documentation)? List the calibration
procedures, spare parts list &
trouble shooting guide.
Executive Management Go / No Go Decision Go / No Go Decision Go / No Go Decision Go / No Go Decision
<-------------------------------------------- Product Management Must Tie It All Together ------------------------------->

4. Samples – Phase / Gate, 5S and Lean Production
Green Technology - Refurbished Equipment
B7XX GS857
 a
M8XX GS827

5. Samples - Phase Gate, 5S and Lean Production
New advanced Technology - New Equipment
Gravostar HS Gravostar Spectrum
Vision 3 - 8KHz
Vision 4 - 12KHz
Digital P-Card
Printed Electronics Technology - New Equipment
MicroStar
AccuPress
Dual
Microscope
LinearDirect Drive

6. Samples - Phase Gate, 5S and Lean Production

7. Manufacturing Costs/Profit/ROI
Machine Project A:

8. Manufacturing Costs/Profit/ROI
Machine Project B: