1. Phase 3: DEVELOPMENT & VALIDATION
PDP Explained
Phase 1: OPPORTUNITY
Phase 2: CONCEPT
Phase 3: DEVELOPMENT & VALIDATION
Phase 4: LAUNCH
Phase 5: ASSESS
PDP (Polaris Development Process) is a 5 Phase Gated Development Process
5 Phases – Stage/Gate process for integrated product development and validation.
4 Levels – Major, Intermediate, Minor and Sourced levels that that can be tailored based on the size and scope of individual programs.
11 Reviews – Allows management to assess programs to prioritize and make Go/No-Go decisions.
7 Builds – Allows teams to validate products and processes from concept to SOP.
Key Deliverables – Provided at builds and reviews during product development.
Framework & Tools to Guide a Project Team in Product Development

2. PDP Build Schedule D Build V Build PI Build PV Build SOP Phase 1
Build Type
Build Code
Responsibility
Phase
Development Unit
(Design Intent, Soft Tooled Parts) D
Engineering
3.6
Validation Unit
(75% Production Tooled Parts) V
3.14
Production Intent Unit
(100% Production Tooled Parts) PI
Manufacturing
3.22
Process Build Unit PB
3.25
Production Verification Build PV
(Production Line)
4.3
Production
PD / SOP
4.7

3. PDP Integration of Supplier Risk Management
Phase 1: Opportunity
Increase Successful Supplier Selection
Overhaul Supplier Selection Process
Total cost analysis, Supplier Process/Quality Capability, Design Capability of Supplier/Polaris
Gate 1
Supplier Selection
Process
Phase 2: CONCEPT
PDP Integration
Gate 2
Phase 3: DEVELOPMENT & VALIDATION
Reduce Supplier Execution Issues
APQP is a method of defining and managing steps needed to develop a quality product.
Manufacturing Feasibility Agreements for producible parts
Supplier Risk Mitigation to control change risk after validation
PDP Integration
Advanced Product Quality Planning
Framework
Gate 3
Phase 4: LAUNCH
Discuss numbering structure of PDP (Phase 1, Step 1 = 1.1, etc.)
PDP Integration
SOP
Phase 5: ASSESS
PDP Integration

4. Advanced Product Quality Planning (APQP)
A structured, collaborative method of defining and managing the proactive steps needed to develop a quality product
Facilitator:
Supplier Quality Engineer
Includes:
Supplier
Quality
Engineering
Levels used to determine key steps:
High: 39 steps
Medium: 28 steps
Low: 21 steps
Key Steps:
Analyze warranty data
Define customer inputs, specifications, KPCs
Design for Manufacture/Assembly
Identify gauging/testing equipment
Develop process flow chart
Conduct process FMEA
Plan and observe Run at Rate
Submit PPAP
Collaborative tool to proactively plan for quality