John M. Cachat, IQS

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Flawless Product Launches
MFG/PROMidwest User Group Fall Conference 2006

• PRESENTED BY
• John M. Cachat, IQS
• Dave Doyle, QAD

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• The current state of the art in most companies
  include MS Project MS Excel. These tools are
  personal productivity tools not enterprise
  business systems.
• This presentation will discuss the technology
  available to execute product launches, not just
  track how far behind you are.

The system must do the work not just report on
it.
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Product Launch Challenges

• What Tools We Have - What We Are Missing
• Identifying Waste In The Process
• Eliminating Waste In The Process
• Optimization QAD And IQS Integration
• Flawless Product Launch - Keys To Success

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• We All Know Poor Launches Are Costly
• Or You Wouldnt Be Here

• Products Arrive LATE
• Competitor Gets Out First Cell Phones Lost Of
  Sales
• Snow Blowers In June Who Cares No Sales
• Cars Without MP3 Players Or IPod Connectors
• Is The Challenge Innovation Or Execution ?
• No One Plans To Be Late
• They Knew What It Took To Produce The Cell Phones
• The Plan Showed Snow Blower Delivery For December
• Design Engineers Have IPods And Are Frustrated
  Too

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Product Launch -- Its About Execution
OYAMA, Japan August 25, 2006 Toyota may
delay the launch of some of its new models, the
companys president said today, as the worlds
No. 2 automaker tries to improve its quality
process in order to reduce a spate of recalls
that is threatening its reputation Watanabe
said that the emphasis was on making sure quality
procedures were properly carried out, rather than
on how much time the process took. Toyotas
shares fell 60 yen, or 0.95 percent today.

Product Launch Its A Bottom Line Issue
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What Is Flawless Launch ?

• It Is About Optimizing Constraints
• Time
• Quality
• Cost
• Identifying Resolving Flaws
• Reduce Variation
• Eliminate Waste
• Life Cycle Process
• Not Departmental
• Not Documents

Quality
Quality
Time
Cost
Engineering
Cost
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What Works What is Missing
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Automotive Product Launch

• Project Plan
• 5 Phases
• 23 Elements

• 1.0 Plan and Define
• 2.0 Product Design and Develop
• 3.0 Process Design and Develop
• 4.0 Product and Process Validation
• 5.0 Feedback, Assessment, Corrective Action

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Plan and Define Program
Project Plan

• 1.1 Voice of the Customer
• 1.1.1 Market Research
• 1.1.2 Historical Warranty and Quality
  Information
• 1.1.3 Team Experience
• 1.2 Business Plan/ Marketing Strategy
• 1.3 Product/ Process Benchmark Data
• 1.4 Product/ Process Assumptions
• 1.5 Product Reliability Studies
• 1.6 Customer Inputs
• 1.7 Design Goals
• 1.8 Reliability and Quality Goals
• 1.9 Preliminary Bill of Material
• 1.10 Preliminary Process Flow Chart
• 1.11 Preliminary Special Characteristics
• 1.12 Product Assurance Plan
• 1.13 Management Support

1.1.2 Historical Warranty and Quality Information
14,000 Parts Per Vehicle x 100
Characteristics Each
1.11 Preliminary Special Characteristics
The Devil Is in the Details
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Its 830 Monday Morning .
Do you know where your details are?

• 2.1 Design FMEA
• 2.2 Design for Manufacturability and
  Assembly
• 2.3 Design Verification
• 2.4 Design Reviews
• 2.5 Prototype Build - Control Plan
• 2.6 Engineering Drawings
• 2.7 Engineering Specifications
• 2.8 Material Specifications
• 2.9 Drawing and Specification Changes
• 2.10 New Equipment, Tooling and Facilities
  Requirements
• 2.11 Special Characteristics
• 2.12 Gages/ Testing Equipment Requirements
• 2.13 Team Feasibility Commitment

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Create and Use the Detailed Information
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But its on my project plan Project
Management vs. Project Execution
Subtitle The Tale of the Dead Docs
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Project Management vs Project Execution

• Project Management tells you
• What, When

• Project Execution
• Is doing the What

• Execution Details are often managed with
  attachments

Attachments Become Dead documents that Generate
Waste !
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FMEAs Have the Power to Manage Risk
Documents and Attachments Versus Business Systems

FMEA CHANGES
FMEA ACTION ITEMS
CONTROL PLAN CHANGES
FMEA RPN ANALYSIS

• FEEDBACKTO ENGINEERING
• Severity
• - Occurrence
• Detection

CONTROL PLAN
FMEA
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Eliminate Waste(Lean)Reduce Variation(Six
Sigma)
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Lean Product Launch
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Tremendous Amount of Non-Value-Added Waste in
the Launch Process
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Example Reporting Nightmare
This Is A HUGE Waste Of Labor To Create And
Update Reports Because There Is Not An Enterprise
Systems That Consolidates The Data For
Reporting Even Worse, Every Department Has
There Own Version
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Reduce Variation Eliminate Waste
Opportunity Gap
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Flawless Launch IQS Bridge the Gap

• IQS fill the gap
• Capture Details
• Coordinate Details
• Communicate Details

• Centralized Data Hub
• One off Details
• Legacy Systems

• Visibility
• Tell me what, and WHY

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QAD and IQS Working Together
Customer Master Supplier Master Item
Master Employee Master Change Management Incoming
Receipts
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NEW PROGRAM APQP
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• APQP TASK LISTS
• Customer
• Internal
• Supplier

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EXAMPLE CHECKLIST
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Engineering Portal
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Management of Characteristics
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DESIGN FMEA
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PROCESS FLOW
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PROCESS FMEA
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CONTROL PLAN
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Engineering Change Management is one of the
biggest challenges in the product launch and
manufacturing
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Engineering Changes 3 Steps
ECR - Engineering Change Request Should We
ECN - Engineering Change Notice Update Everything
ECO - Engineering Change Order Do It
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Employee Suggestion Life Cycle
Reject Revoke Reroute
PCR Creation
Release Notices
Route for Approval Electronic Approvals
comments
NO
YES
Release/Distribute
Convert to PCO
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Change Management Workflows
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Change Management ECR, ECN, ECO
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Robust Change Management Options

• Single Change Request Against Multiple Products
• Single Product to Multiple Change Requests
• Single Product that Affects Multiple Products

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Product Change Life Cycle
Reject Revoke Reroute
PCO Creation
Release Notices
Route for Approval Electronic Approvals
comments
NO
YES
Release/Distribute
Planning Systems
Dates
Implementation
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Product Change Request Approvals

• Workflow
• Approved By List
• Includes Hierarchy And Stop If Not Approved Then
  Automatically Posted To Change Request When
  Product ID Is Entered
• Email Notification Is Available
• Escalation Available

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Identify and Eliminate Waste in the Launch
Process
Can you identify your current process? Use
integrated tools to streamline.
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Incorporate Integrated tools
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Summary Flawless Launches

• Single Source of Information is Critical
• Consolidate Stand Alone Tools
• Use Existing Enterprise Software Data
• Reduce Variation, Eliminate Waste
• Solve the Execution Problem

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Why IQS and Why Now?

• Off the Shelf Integration with QAD
• Tangible Savings Today
• Extension QAD Investment
• Document Authoring Solution
• Competitive Opportunity
• Faster Time to Market
• Lower Warranty Costs
• Early Warning System
• Lower IT Costs

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Q A
Flawless Product Launches
IQS, Inc. 19706 Center Ridge Road Cleveland, Ohio
44116 440-333-1344 www.iqs.com