1. Development Process (3.2.3) Process Owner Presentation
4/24/2017
Development Process (3.2.3) Process Owner Presentation
Cal-Comp USA
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2. Cal-Comp USA Employees - 500 (San Diego, Indiana & Reynosa)
4/24/2017
Cal-Comp USA
Employees (San Diego, Indiana & Reynosa)
AS9100, ISO/TS (Automotive), ISO 9001 & (Medical)
Aerospace & Military Customers:
Use one of the following:
1.1.1 Strategic Planning Process Leadership Communication Process Organizational Performance Review Process Continuous Improvement Management Process Workforce Development Integration Process Supply Chain Integration Process New Product Startup Process 2
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3. Process Overview / Criteria
4/24/2017
Process Overview / Criteria
3.2.3 Development Process
How does your organization design and develop new products or services?
How are advanced techniques such as Six Sigma, Design of Experiments, Design to Cost, Design for Manufacturability integrated into your operations?
How are customers and suppliers integrated into your development process?
How is the development process reviewed and improved?
Use one of the following:
1.1.1 Strategic Planning Process Leadership Communication Process Organizational Performance Review Process Continuous Improvement Management Process Workforce Development Integration Process Supply Chain Integration Process New Product Startup Process 3
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4. Advanced Product Quality Planning-APQP (Design For Six Sigma-DFSS)
4/24/2017
Our Key Practices
Advanced Product Quality Planning-APQP (Design For Six Sigma-DFSS)
AS Product Realization
1.3.1 New Product Start-Up Process (APQP)
Development Process 3.2.3
Production Preparation Process 3-P
Production Part Approval Process & FAI
List the key activities that your company performs related to this process
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5. 4/24/2017
Things We Did Right
Customer-focused Multi-disciplined Teams Developed at 1st Engagement With Champions
Program Manager
Manufacturing / Quality Engineer
Test Engineer
Value-Stream Manager
Production Planner
Procurement Specialist
Cell Leads
Key Supplier Representatives
List the key activities that your company performs related to this process 5
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6. Things We Did Right Advanced Product Quality Planning Time-Line
4/24/2017
Things We Did Right
Advanced Product Quality Planning Time-Line
Concept Initiation / Approval
LP- Lab Prototype (Proto)
MP- Mfg. Prototype (Pilot)
PP- Production Prototype (Launch)
Program Approval
Planning
Planning
Product Design & Dev.
Process Design & Development
Product & Process Validation
Production
Highlight successful experiences and outcomes from the practices on slide 3
Feedback Assessment & Corrective Action
Product Design & Development Verification
Process Design & Development Verification
Feedback Assessment & Corrective Action
Plan & Define Program
Product & Process Validation
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7. Built Quality In With Core Tools
4/24/2017
Built Quality In With Core Tools 7
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8. DFMEA & PFMEA Benefits Design Failure Mode Effects Analysis - DFMEA
4/24/2017
DFMEA & PFMEA Benefits
Design Failure Mode Effects Analysis - DFMEA
Design For Cost Reduction - DFCR
Process Failure Mode Effects Analysis - PFMEA
Design For Manufacturability - DFM
Design For Assembly - DFA
Design For Test - DFT
Design For Serviceability – DFS
Mistake-proofing & Process Controls
List the key activities that your company performs related to this process 8
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9. Multiple PDCA Experiments
Concept Initiation / Approval
Program Approval
Prototype
Pilot
Launch
Feedback Assessment & Corrective Action
Product & Process Validation
Process Design & Development Verification
Product Design & Development Verification
Plan & Define Program
Planning
Product Design & Dev.
Process Design & Development
Production

10. Begin Lean With 3P At Prototype
4/24/2017
Begin Lean With 3P At Prototype
3P - Production Preparation Process
Note: Each color represents a different operator’s work cycle 10
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11. VSM From Raw Material to USAF
4/24/2017
VSM From Raw Material to USAF 11
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12. Continual Improvement
4/24/2017 12
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13. 4/24/2017
Things We Learned
Empowered Customer-focused Multi-disciplined Teams – Main Ingredient for Success
Product & Process Intimacy – Well Worth the Effort
Core Tools - Living Records of Our Very Best
3P & APQP Work Hand-in-glove – Quality, Cost Reduction & Productivity Improved Together
Preventing Problems (Mistake-proofing) & Removing Waste in Advance – Smooth & Successful Launches
Improved DFX Capabilities – More Value-added Services for Our Customers
Ultra Effective Ramps – More Like Step-functions
Highlight learning experiences and things that didn’t go well the first time – “Lessons Learned” 13
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14. Contact: Kenny Heifner
4/24/2017
Questions
Thank You
Contact: Kenny Heifner
(858)
Enter your contact information.
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