Build4Scale · 2017-12-20 · U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE...

Introduc)onU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org

Build4ScaleMod0CourseIntroduc)on

Introduc)onU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org

2

Whyisdesignimportant?Mo)va)on

Source:1989Munro&Associates,Inc.

Decisionsmadeduringthedesignprocesshavesignificanteffectsonthesuccess(orfailure)ofyourproduct


WhyUseBuild4Scale?

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o Keyconsidera)onssoyouwillmakebeFerdecisionsearlier,savingyou)meandmoney

o Knowingwhattoexpectwhenmovingfromprototypetoopera)ngatscalemeansyouwillbemoreprepared

o Materialscanbefollowedconsecu)velyorad-hocdependingonyourneeds

Asktherightques?onsattheright?me

Source:1989Munro&Associates,Inc.


4

Nowthatyou’vebuiltasuccessfulprototype,youwanttobeginmassproducingyourproduct

Source:DonResisingerApril2016FortuneMagazineInsideaFlextronicsfactoryinFortWorth,Texas.CourtesyofTheWallStreetJournal

Build4ScaleTeachesManufacturingFundamentals


5Source:UCBerkeley3/27/2017

Except,youdidn’ttakethatclass……

Build4ScaleTeachesManufacturingFundamentals


ModuleOutline

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o Productdesignversusmanufacturinglevelo Whereyoushouldbe:Module1o Whereyouaregoing:Modules2–7


PRODUCTDESIGNOBJECTIVESMarketResearch

DesignResearchFeasibility

DevelopmentQualifica)on

FieldReadinessLaunch

MfgCapacity

MANUFACTURINGREADINESSLEVELSLevels: 109987654321

MfgDevelopmentManufacturingResearch

MfgCapability

Produc)on

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ProductAndDesignProcessVersusmanufacturingreadinesslevels(MRLs)

ConceptandFeasibility Defini)on

ProductandProcessDesign

ImplementandValidate

Produc)onandStock

LaunchandClosure

Pre-alpha Alpha Beta Pilot Ramp Scale

PHAS

ES

BUILDS

EngineeringValida?on

DesignValida?on

ProcessValida?on

ConceptValida?on


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o Atthispoint,youshouldhaveaclearunderstandingofyourcustomerandyourmarketincludingthecustomer’sneedsandyourvalueproposi)on

o Youshouldalsohaveaprototypethatlooksandfunc)onslikeyourproposedproduct;notallcomponentswillbeproduc)on-ready,yourprototypeshouldallowcustomerstoseeandunderstandyourvalueTheprototypeshouldconfirmthefeasibilityofyourconcept

WhereYouShouldBe

Conceptand

FeasibilityDefini)on



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida4on


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o Nowyou’rereadytomovealongthepathtoproductlauncho Decisionspreviouslymadeforexpediencynowneedtobere-examinedfortheirsuitabilityatscale

o Solu)onsthatworkedinthelabneedtobeevaluatedfortheirproduc)on)meandcostathighervolume

WhereYouAreGoing

Conceptand




Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida4on


10

Module1

o Module1allowsyoutoassessyourneedsanddeterminewhereyoumightwanttostartintheBuild4Scaletraining

Self-Assessment

Conceptand




Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida4on


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Module2

o Module2providesanoverviewofthetoolsneededtoturnyourprototypeintoanactualdesignpackage:— Module2A:describeshowtocreateabillofmaterials(BOM)andbillofprocess(BOP),whichspecifythecomponentsandprocessesneededforyourproduct

— Module2B:discussesproductlifecyclemanagement(PLM)toolsthatallowyoutotrackdesigndocuments,createtheBOM,andensurethatdesignscommunicatethenecessaryinforma)on

DetailedDesignPackage

ConceptandFeasibility Defini)on Productand

ProcessDesignImplementandValidate

Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS

EngineeringValida4on

DesignValida?on

ProcessValida?on

ConceptValida?on


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Module2(cont.)

o Module2providesanoverviewofthetoolsneededtoturnyourprototypeintoanactualdesignpackage:(cont.)— Module2C:describeshowtocreatequalitystandardsfromcustomerneedsanddeterminewhatcangowrongwithyourdesign(andhowtofixit)

DetailedDesignPackage



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida?on


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Module3

o Module3focusesonensuringthatyourmaterialsandmanufacturingchoicesareeconomicallyviableandmeetcustomerneeds:— Module3A:describeshowtodeterminethecostsforyourproductandensuretheyareinlinewiththemarket(thisservesasthefounda)onforotherdesigndecisions)

— Module3B:providesbackgroundinforma)onondifferentmaterialclassesandhighlightsproper)esthatensureselectedmaterialsmeetcustomerneedseconomically

DesignForManufacturing



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida4on

ProcessValida?on

ConceptValida?on


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Module3(cont.)

o Module3focusesonensuringthatyourmaterialsandmanufacturingchoicesareeconomicallyviableandmeetcustomerneeds:(cont.)— Module3C:describesalterna)vemanufacturingprocessesandtheircostandinvestmentimplica)ons

DesignForManufacturing



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida4on

ProcessValida?on

ConceptValida?on


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Module3(cont.)

o Module3coversdesigningyourproductandprocesses:— Module3D:providesguidelinestoensurethatproductsaredesignedtobemanufacturedandassembledatlowcostwithhighquality

— Module3E:describeswaystoassessyourproductandensurethatitdoesn’tfailpriortotheendofitsusefullife

— Module3F:providesanintroduc)ononhowtodesignandfabricateelectroniccomponentsthatmeetcustomerneedsandproviderobustperformance

DesignForAssembly/Reliability



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida4on

ProcessValida?on

ConceptValida?on


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Module4

o Module4describeshowtouseyourbetaprototypemostefficiently

o Thismodulehelpsyoudeterminewhichques)onsyouwantanswered,howbesttogetthatdata,andhowtomoveforwardtoproductlaunch:— Module4A:highlightsques)onsofinteresttoyourcustomerpriortoscalingproduc)onandhowyoucanuseprototypestoanswerthem

BetaPrototypeAndTestPlan



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida4on

ProcessValida4on

ConceptValida?on


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Module4(cont.)

o Module4describeshowtouseyourbetaprototypemostefficiently:(cont.)— Module4B:discussestheimportanceofusingactualmanufacturingandassemblyprocessesandhowtoensurethatsuppliersprovidethenecessarycomponents

— Module4C:discusseswaystoassessthebetaprototypeandtrade-offsassociatedwithalterna)veassessmentmethods

— Module4D:discusseshowtodocumentfeedbackandissuesassociatedwithdesignchanges

BetaPrototypeAndTestPlan



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida4on

ProcessValida4on

ConceptValida?on


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Module5

o Module5describeshowtobuildthesupply-and-distribu)onplanforyourproduct

o Thismodulehelpsyoutoselectandnego)atewithvendorsandensurethatyourproductreachesthecustomeron-)meandinfull:— Module5A:discusseskeyques)onsrelatedtomakingorbuyingacomponentandselec)ngandnego)a)ngwithsuppliers

Communica)onAndSelec)on

Conceptand

FeasibilityDefini)on Productand


Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module5(cont.)

o Module5describeshowtobuildthesupply-and-distribu)onplanforyourproduct:(cont.)— Module5B:discussesuseofenterpriseresourceplanning(ERP)andmanufacturingresourceplanning(MRP-2)toolsandhowtoselectthetoolyouneed

— Module5C:describeshowtousealterna)veforecas)ngmethodsandintegrateyourenterpriseresourceplanning(ERP)systemtoensurethatyoudeliverthenecessaryproducttoyourcustomerson)me

Nego)a)onAndDistribu)on

Conceptand



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module5(cont.)

o Module5describeshowtobuildthesupply-and-distribu)onplanforyourproduct:(cont.)— Module5D:describeshowtoshipyourproducteconomicallywhilemee)ngcustomerandregulatoryrequirements

Nego)a)onAndDistribu)on

Conceptand



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module6

o Module6discussestheregulatory,cer)fica)on,andqualityneedsofyourproduct

o Thismodulehelpsyoudeterminewhatcer)fica)onyourproductneeds,whichregulatoryregimesyourproductissubjectto,andhowtoensureconsistentproduc)onqualityforyourmanufacturingprocesses:— Module6A:discussesthedifferencesbetweenregula)onandcer)fica)onandtheeffectsbothhaveonyourproductlaunch

Regula)onAndCer)fica)on

Conceptand



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module6(cont.)

o Module6discussestheregulatory,cer)fica)on,andqualityneedsofyourproduct:(cont.)— Module6B:coverscertainindustriesthatmayhavemoreregulatoryrequirements,andhowtocomply

— Module6C:describeshowtotranslatecustomerinputsintoregulatoryandcer)fica)onneedsandhowtousebenchmarkingtodetermineregula)onandcer)fica)on

Regula)on/IndustryStandards

Conceptand



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module6(cont.)

o Module6discussestheregulatory,cer)fica)on,andqualityneedsofyourproduct:(cont.)— Module6D:describeshowtodeterminewhatvariousmanufacturingprocessescando,andhowtoensurethatthey’recapableofconsistentlymee)ngcustomerneeds

Regula)on/IndustryStandards

Conceptand



Produc)onandStock

LaunchandClosure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida4on

ConceptValida?on


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Module7

o Module7covershowtosustainandgrowyourbusinesso Thismoduledescribeshowtoconsistentlyprovidequalityproductstoyourcustomers,dealwithanyqualityissues,andgrowyourbusiness:— Module7A:discusseshowtoensurethatyou(andyoursuppliers)areconsistentlyproducingproductsthatmeetyourcustomers’needs

SustainingQualityAndGrowth

Conceptand


ProcessDesignImplementand

ValidateProduc)onandStock

Launchand

Closure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida?on


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Module7(cont.)

o Module7covershowtosustainandgrowyourbusiness:(cont.)— Module7B:explainshowtoiden)fyandresolvepoten)alissuesasyourbusinessgrowsandproduc)onincreases

— Module7C:discussesmethodsforcapturingcustomerdataandhowtoreplaceproductsthatdon’tmeettheirexpecta)ons

— Module7D:discusseshowdifferentcostcategoriesgrowwithyourbusinessandhowtofundthatgrowth

QualityAndWarrantyPlan

Conceptand


ProcessDesignImplementand

ValidateProduc)onandStock

Launchand

Closure


PHAS

ES

BUILDS


DesignValida?on

ProcessValida?on

ConceptValida?on

Build4Scale · 2017-12-20 · U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE...

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Transcript of Build4Scale · 2017-12-20 · U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE...