New Product Development Process

1
New Product Development Process

• 1. Product planning Develop design brief
• 2. Project planning Team formation, resources
• 3. Identify interview customers
• 4. Develop customers requirements
• 5. Develop engineering requirements
• 6. Perform benchmarking
• 7. Set performance targets
• 8. Develop PDS
• 9. Develop concepts

2
Concept Generation

• Facts
• Concepts are best generated by individuals!
• Concept selection is best performed by groups

3
The five-step Methodology
Clarify Problem
Search Externally
Search Internally
Sub-problems
Explore Systematically
Reflection
4
Step - I Clarify

• Review all the specification targets in PDS
• Perform a functional decomposition
• Divide complex functions into many simpler ones.
• Follow the flow of materials, signals, or energy
  to determine what functions are required.
• Avoid specific solutions.

5
Functional Decomposition

• Example Cardboard pallet forming device
• Following material flow
• Raise and position cardboard sheets
• Slide cardboard out of loading storage
• Apply glue
• Position cardboard for forming
• Form cardboard crease marks
• Bend and form reinforcement shape
• Insert reinforcement shapes manual
• Close flaps

6
Functional Decomposition

• Position cardboard for forming
• Apply force to cardboard
• Guide cardboard
• Stop cardboard
• Secure cardboard for bending
• Prevent cardboard motion laterally.
• Prevent cardboard lift up.

7
Functional Decomposition

• Signal flows
• Sense cardboard level
• Trigger feed mechanism
• Verify the cardboard position
• Sense cardboard face contact
• Sense edge contact
• Trigger glue application

8
External Search(Pin Remover)

• Direct competition - Same products - None
• Similar functions on related products (Natural)
• Bearing removers
• Cork removers
• Pneumatic hammers and nailers
• Car jacks
• Vises
• Industrial presses and hammers
• Winches

9
Searching for Ideas

• External Sources of Ideas
• Patents (Overall function or sub-functions)
• Published literature
• Research and trade journals
• Interview lead users
• Consult experts
• Benchmark related products
• Internet

10
Searching for Ideas

• Search internally - Brainstorming
• Visualize
• Work individually at first
• Generate a lot of ideas
• Allows extracting useful features
• Stimulates other ideas
• Include ideas which may seem infeasible
• Use graphical or physical models

11
Exploring Systematically

• Organizing solution fragments
• Concept Classification Tree
• Classifies possible approaches to a sub-problem
• Allows early pruning of the branches.
• Branches represent different approaches to be
  further explored by different individuals.

12
Exploring Systematically

• Example Power sources.
• Example Cardboard feeder (roller, suction,
  pusher)
• Example Pad washer nozzle pad surface
• Move nozzles over pad only
• Move pad and nozzles
• Move pad only
• Example Bolt tester power and force source

13
Functional Decomposition
14
Exploring Systematically

• Concept Combination Table
• Combines solutions to sub-problems
• Some combinations may not make sense