The document discusses the product development cycle and project management processes. It begins by outlining the 5 phases of product development: idea generation, planning, development, validation, qualification, and production. It then describes the 4 key steps of project management: 1) presenting ideas, 2) planning the work, 3) working the plan, and 4) learning from experiences. For each step and phase, it provides details on the associated tasks and goals. The overall intent is to explain how effective project management can help navigate the product development cycle.

1. 11MARCH04
Product Development Cycle and Project
Management Process
The Product Development
Cycle in Today’s Manufacturing
OVERVIEW
1. Explain the product development cycle
2. Define project management processes
3. Relate #1 and #2
4. Discuss the tasks behind each process
5. Suggest simple communication tools
Bob Carson
March 11, 2004

2. 11MARCH04 2
Product Development Cycle and Project
Management Process
Expected Outcomes
 Individuals will understand:
 product development in today’s industry
 processes of project management
 value of simple communication
 Individuals will recognize the value of effective
project management skills in today’s product
development cycle

3. 11MARCH04
Product Development Cycle and
Project Management Process 3
Common Definitions
 Product Development Cycle: the period of time
needed to complete the set of events that
develops an idea into a quality product
 Process: the ordered set of events required to
achieve a quality result and ensure robust,
repeatable results
 Project: the organization of the team’s
commitment to deliver a product
 Project Management: the control of team
behaviors across the Product Development Cycle

4. 11MARCH04 Product Development Cycle
and Project Management
4
Motivation
• Engineers should learn about today’s
development practices
• An engineer’s skill set should
parallel industry’s expectations
• Efficient individuals develop
effective project management skills

5. 11MARCH04 5
Product Development Cycle and Project
Management Process
Phases of the Product
Development Cycle
 Phase 0 - Generate Idea
 Phase 1 - Plan
 Phase 2 - Develop
 Phase 3 - Validate
 Phase 4 - Qualify
 Phase 5 - Produce

6. 11MARCH04
Product Development Cycle and
Project Management Process 6
Product Development Phases
Phase 0
Sell Ideas
1
Plan
2
Develop
3
Validate
4
Qualify
5
Produce
Goal Generate
many
ideas
Develop
Plan
Advance
idea to
product
Proof of
specs
Proof of
build
Robust
process
Process Develop
Ideas into
Proposal
Plan the
work for
the Team
Engineer
Functional
Models
Test
Proto
units
Build &
Test Pilot
units
Release
Product
to Sell
Main
Artifact
Initial
Project
Summary
Gantt
Chart
Working
Modules &
Prototypes
Solid
System
Proto
Working
Product
Quality
Product
Owner Project
Champion
Core
Team
Extended or Core Team Member

7. 11MARCH04 7
Product Development Cycle and Project
Management Process
Project Management Process Steps
1. Present an idea
2. Plan the work
3. Work the plan
4. Learn from experiences

8. 11MARCH04
Product Development Cycle and
Project Management Process 8
Process–Phase Relationship
Project
Mgmt
Process
Steps
Phase 0
Ideas
Phase 1
Plan
Phase 2
Develop
Phase 3
Validate
Phase 4
Qualify
Phase 5
Produce
1 Develop
Ideas
2 Plan the
work
3 Work the Plan
4 Learn from positive and negative events

9. 11MARCH04
Product Development Cycle and
Project Management Process 9
Process Step 1. Present an Idea
Phase 0
• Collect ideas
• Consider customers
• Know stakeholders
• Write proposal (Initial Project Summary)
QUICK

10. STEP 1
Product Development Cycle and
Project Management Process 10
Ideas come from Many Sources
• Customer wants
• Customer needs
• Competitor products
• Competitor plans
• Marketing/sales logs
• Organizational strategies
• Society attitudes and opinions

11. STEP 1
Product Development Cycle and
Project Management Process 11
Consider All Customers
• External customers buy products that
provide the lifeblood for the organization
• Internal customers have objectives linked
to products that meet organizational goals
• Business partners help develop products
to further everyone’s organizational goals
• Carefully consider each customer need

12. STEP 1
Product Development Cycle and
Project Management Process 12
Know all Stakeholder Agendas
• Understand all external customer plans
• Check alignment of the idea with the
current organizational strategies
• Solicit input from all internal customers
and provide continuous feedback
• Uncover any hidden agendas through
open conversations and discussions

13. STEP 1
Product Development Cycle and
Project Management Process 13
Develop the Initial Project
Summary (IPS)
 Goal
 Product Roadmap
 Key Selling Points
 Key Customers
 Proposed Team
 Business Case
 Recommendation to decision-makers
Quick

14. 11MARCH04
Product Development Cycle and Project
Management Process 14
Process Step 2. Plan the work
Phase 1
Incorporate new organizational input
Select the team
Identify tasks
Link deliverables to milestones
Anticipate showstoppers
Define tradeoffs
Freeze the plan

15. STEP 2
Product Development Cycle and Project
Management Process 15
Consider new input
Decision-makers typically set direction for
the project at the Phase 0 exit review
(quality, performance, schedule and cost)
Meld those inputs into the IPS as you
develop the project plan
Oversight or ignoring organizational
direction can be costly down the road

16. STEP 2
Product Development Cycle and Project
Management Process 16
Select the teams
The core team may
include 8 members
The extended team
contains as many
members as needed
to complete the work
– BUT time, humans
and money are never
infinite resources
CORE TEAM
– Research
– Quality
– Hardware
– Software
– Mechanical
– Manufacturing
– Marketing/Sales
– Finance

17. STEP 2
Product Development Cycle and Project
Management Process 17
Identify the tasks
Break down the work into tasks for each
project phase
Assign owners
Assign proposed due dates
Set milestones and review dates
Iterate to a potential plan

18. STEP 2
Product Development Cycle and Project
Management Process 18
Link deliverables
Match deliverables to milestones by phase.
Plan for deliverables that are not tied to key
milestones. What are some examples of key
deliverables?
– New parts or components
– Module prototypes
– System prototypes
– Marketing collateral
– New test equipment and rework systems
– New manufacturing equipment or machines

19. STEP 2
Product Development Cycle and Project
Management Process 19
Define tradeoffs
Showstoppers need defined before
finalizing the plan
Establish tradeoffs to give the team clear
direction should known risks develop
This task avoids wasted time later in the
project. It shows the decision-makers a
team’s due diligence to project success

20. STEP 2
Product Development Cycle and Project
Management Process 20
Freeze the plan
Establish reporting structure
Define project metrics - QPSC
Set firm values
– Phase Schedules
– Cost
– Qualification date
– Production date
Recommend a final plan for approval

21. 11MARCH04
Product Development Cycle and Project
Management Process 21
Process Step 3. Work the plan
Phases2-5
• The team must report on progress and address
any issues as the project unfolds. The concepts
for Work the Plan include:
– Commit and deliver to plan
– Monitor and report metrics with data
– Discuss obstacles and engage stakeholders
– Communicate change
– Recommit and deliver to change

22. STEP 3
Product Development Cycle and Project
Management Process 22
Commit and Deliver
• “Can do” attitudes ensure project success
• Cohesive teams produce a synergy

23. STEP 3
Product Development Cycle and Project
Management Process 23
Report routinely
• Report project progress using data
• Communicate project status to all decision-
makers and stakeholders with Quality,
Performance, Cost and Schedule metrics
• Suggest recommendations when negative data
identifies a need for change. Never report a
problem without a recommended solution

24. WEEKLY STATUS
REPORT
Product Development Cycle and
Project Management Process
24
Date: 11MAR04 Status Report: 04-123 Project Manager: Carson
GREEN
RED Quality
Performance
Schedule
Cost
Year-to-Date Project Figures
Project Start Date:10DEC04
Current Phase: Validation
Original End Date: 2APR04
Current End Date: 27APR04 5MAY04
Project Budget: $_____
% Under Budget _____
Expected $$ Overrun ___
% Over Budget _____
Upcoming Activities
UACT 1
UACT 2
UACT n
Start Date
Completed Activities
CACT 1
CACT 2
CACT n
Completion Date
Team Member Summary of current week’s activities Due Date Status
Andersen Finalized the test fixtures for Proto3A
Modified the test code for UL testing platform
20MAR04
24MAR04
Green
Green
Zeller Modified test fixtures for Proto4A
Build self locking fixturing for Mfg Qualification tests
15MAR04
10MAR04
Green
RED
Issue Summary Action Owner Due Date
Schedule Beryllium Copper late in arriving – due 12MAR Will work OT on 13-14MAR HILL 15MAR
Comments: Low risk item: Mfg Engr has high confidence that Production tests will still meet schedule

25. STEP 3
Product Development Cycle and Project
Management Process 25
Discuss obstacles with
stakeholders
• Discuss the effects of any obstacle with every
stakeholder and ensure understanding
• Engage all stakeholders to meet each one’s
needs. Over-communicate to ensure
concurrence with change plans
• Submit recommendations to decision-makers
and stakeholders. Welcome comments and
feedback on any change plans

26. HYPOTHETICAL
Product Development Cycle and Project
Management Process 26
Cost of Changes
$500 $5,000
$50,000
$250,000
$500,000
$1,000,000
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
900,000
1,000,000
Phase 0 Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
Cost

27. STEP 3
Product Development Cycle and Project
Management Process 27
Communicate change
Never surprise anyone
• Over-communicate when change happens
• Ensure all decision-makers and stakeholders
agree with any new tasks or plan changes

28. STEP 3
Product Development Cycle and Project
Management Process 28
Recommit and Deliver
• Change plans get the scrutiny of many
• Recognize there may be lots of emotion around
any change in plans. It’s the team’s responsibility
to plan accordingly
• Emphasize commitment and delivery to the
change plan. It may be more important than
achieving the original plan.

29. 11MARCH04
Product Development Cycle and
Project Management Process 29
Process Step 4. Learn from experience
Phases 0-5
 Professionals use well-documented
events to reinforce good behaviors
and discourage bad ones.
 Continuous improvement discipline
demands everyone to learn from
past experiences – shed the bad and
share the good.

30. STEP 4
Product Development Cycle and
Project Management Process 30
Learn from experience
 Document events
 Train the positive
 Toss the negative
 Teach your world

31. STEP 4
Product Development Cycle and
Project Management Process 31
Document events
 Every project experiences both
positive and negative events
 Record all events using accurate data

32. STEP 4
Product Development Cycle and
Project Management Process 32
Toss the negative
 Every event during a project is an
opportunity for improvement.
 Eliminate these events from practice
by modifying processes and work
instructions to prevent recurrence.
 Live the NMI discipline

33. STEP 4
Product Development Cycle and
Project Management Process 33
NMI Discipline
 NameIt: If a process is not defined
the you do NOT know what to do
 MeasureIt: You cannot measure a
process unless you have defined it
 ImproveIt: A process cannot be
improved unless you can measure it

34. STEP 4
Product Development Cycle and
Project Management Process 34
Train the positive
 Every event during a project is an
opportunity for improvement.
 Incorporate these events into practice
by modifying processes and work
instructions to ensure recurrence.
 Live the NMI discipline

35. STEP 4
Product Development Cycle and
Project Management Process 35
Teach your organization
 Both positive and negative
experiences provide valuable insight
to others.
 Proactively share the “Lessons
Learned” across the organization.
Educate others of possible benefits in
other areas of the organization.

36. 11MARCH04
Product Development Cycle and
Project Management Process 36
Conclusions
Process
Steps
Phase 0
Ideas
Phase 1
Plan
Phase 2
Develop
Phase 3
Validate
Phase 4
Qualify
Phase 5
Produce
1 Develop
Ideas
2 Plan the
work
3
Work the Plan
4 Learn from positive and negative events