3. Project Introduction
• The new product evaluated for this case study has the following project scope
– Introduction of 700+ custom injection molds
– Collaboration between 50+ design engineers
– Communication between 3 different Geographic Regions
– Aggressive Release Schedule
• The success of meeting product development objectives depends on the utilization of effective communication
strategies from project initiation through production.
• The adoption of a the correct plastic part review process and release planning was at the crux of project.
3
4. Mission, Objectives, and Goals
4
MOGSA Structure
1) Identify the Project Mission
2) Identify the Supporting Objectives
3) Identify the Supporting Goals
MissionObjectivesStrategiesActionsGoals
Reduce Costs
Make Quality
Products
Best system for
Plastic Part Design
Release
Enable parts
on TIme
Timing Plan
Increase
Communicati
on
Reduce
Variable
Costs
Reduce Fixed
Cost
Provide
Mentorship
Enable New
Technologies
Relationships
with
Stakeholders
6. Process: Strategies and Actions
MOGSA Structure6
4) Compare the Alternatives
5) Identify the resulting actions
MissionObjectivesStrategiesActionsGoals
Reduce Costs
Make Quality
Products
Determine
Gate
Placement
Determine
Tool Criteria
Optimize
Design for
Plastic
Best system for
Plastic Part Design
Release
Enable parts
on TIme
Timing Plan
Reduce
Production
Issues
Increase
Communicati
on
Validate
Design Using
Simulation
Reduce
Variable
Costs
Reduce Fixed
Cost
Provide
Mentorship
Collaborative
Team
Formation
Linear
Release
System
Provide
Tooling DFM
Enable New
Technologies
Relationships
with
Stakeholders
Prioritize
Workflow
7. The Round-Table Process
• To solve problems associated with project complexity, the plastic product
development process evolved to utilize increased face-to-face
communication as the primary method of communication
• The team used the term “Round-Table Review” to describe the collaborative
team system and process that was implemented
7
8. “noting or pertaining to a conference,
discussion, or deliberation in which
each participant has equal status,
equal voice, and equal time”
Definition of Round Table
8
9. • Guiding Visions
– Organize a small team of peers
– Keep it Simple
– Have Respect
– Trust your team
– Focus on problem identification
– Evaluate using different perspectives
• Meetings are informal in nature, and do not use systematic rating systems or advanced evaluation techniques.
• Establish some discussion points to keep the review process flowing
About the Process
9
10. Discussion Points
Perspective #1 Project Management
– What is the schedule?
– Is there a prioritization for part or component?
– Assignment of a plastics owner to provide a point of contact
10
Project Management | Tooling | Plastic Design | Plastic Processing
11. Discussion Points
Perspective #2 Tooling
– What is the estimated usage?
– Is the part cosmetic?
– Establishment of gate strategy to obtain design objective
– Identification of any special requirements
11
Project Management | Tooling | Plastic Design | Plastic Processing
12. Discussion Points
Perspective #3 Plastic Design
– Discuss the part function?
– Natural Cavity/Core Split of the design
– Top level design rule violations
– Discussion on alternative plastic design solutions that better accomplish the design
goals
12
Project Management | Tooling | Plastic Design | Plastic Processing
13. Discussion Points
Perspective #4 Plastics Processing
– Identification of the material
– General Processing Discussion
– Identify long term concerns with production
13
Project Management | Tooling | Plastic Design | Plastic Processing
15. 0
10
20
30
40
50
60
70
80
90
100
Mold Simulation
Before
After
Spent more time performing simulations to support the Design
Develop an injection mold manufacturing strategy
– Developed and validated of Gating Strategy
– Identify thick and thin areas
– Validate the design details/features
– Predict cosmetic defects
15
Face to Face communication of Simulation results enables non molding experts to
understand the value of the tools.
16. Plan for Parts on Schedule
Project management and planning enables discussions
regarding design release and production planning.
Establishment of release schedule
• Clear communication with vendors to understand
resource utilization and limitations
• Clear communication with engineers to understand
resource utilization and limitations
• Parts released to vendors had improved
manufacturability. Enabled to hit the ground running.
16
Both internal and external stakeholders benefit from communication
0
10
20
30
40
50
60
70
80
90
100
Schedule Improvements
Before
After
17. Explore using Alternate Methods to Solve Design Problems
Early discussion allows the team to focus on solutions up front
and to plan for utilization of new production methods
Some of the new technologies adopted during this process
were
– Two Shot Injection Molding
– Gas Assist Injection Molding
– Sequential Valve Gate
– Family Tooling
17
Collaborative Review Process enables the Assessment and Implementation of New Ideas
and Methods
0
10
20
30
40
50
60
70
80
90
100
New Technology
Before
After
18. Collaboration Provides Mentorship to the Participants of the Group
Discussing and collaborating on technical issues resulted
in team members learning and knowledge transfer.
The following skill areas showed improvement:
– Project Management
– Part Design
– Tool Design
– Processing
– Communication
– Mold Simulation
18
Working together helps team members learn and share.
Making the team and product better
0
10
20
30
40
50
60
70
80
90
100
Skill Level
Before
After
20. Conclusion
The product quality, cost, and execution all benefited from the use of the Round-Table design review discussions. These
improvements were measured by the assessment criteria discussed.
– Mold Simulation Utilization
– Improvement in Parts on Time
– New Technology Adoption
– Development of employee skillset
20
Above all the group members and culture of the plastics organization of HP inc.
improved. The change has enabled better technology assessment and planning within
the organization.
23. 23
PANEL DISCUSSION:
Bridging the Departmental Divide
Cross-functional empathy: Getting the interdisciplinary gears to mesh
MODERATOR:
• David Dombrowski, Director – Industrial Design & Innovation, Pfizer Consumer Healthcare
PANELISTS:
• Sam DuPlessis, Design Lead, GE Appliances & Director, FirstBuild
• Denise Greenwell, Global Market Development Mgr., Berry Plastics Corp.
• Albert McGovern, Director - Mechanical Engineering, Shure Inc.
• David Tucker, Plastics Sourcing Engineer, HP Inc.
24. 24
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• Design by Glenn Beall
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