制造业新产品导入流程模板.doc

制造业新产品导入步骤模板Scope 范围-This procedure covers new product introduction in AAA (Suzhou). 凡导入AAA苏州工厂制造新产品，均依本程序文件要求。New product introduction include NPD (New Product Development) and NPT (New Product Transfer).新产品导入包含新产品开发和新产品转移。 Objective 目标- To make assure new product introduction in AAA (Suzhou) is under control.确保AAA苏州工厂新产品导入处于受控状态。Applicability 适用性-This procedure applies to only AAA (Suzhou) facility.此程序文件仅适适用于AAA苏州工厂。Definition 定义-New product introduction is a project management process.Project initiation means when one factory NPI Project leader (Project Manager)accept authorization from local management, project close means when new product is delivered to mass production after ramp up.新产品导入是一个项目管理过程。当一个当地新产品领导人接收管理层授权意味着项目开启，当新产品进入爬坡生产以后大批量生产意味着项目结束。Responsibilities 职责/ Output 输出汇报-1. POM ( Plant Operation Manager) and Management工厂运作经理和管理层1.1 Assign factory NPI Project Leader (Project Manager)for each project with management, give him/her very clear assignment and authorization. NPI Engineer also can be NPI Project leader if the project is small.为每个项目任命工厂新产品导入项目领导人(项目经理)，给此人清楚任务分配和授权。假如项目较小，新产品导入工程师也可成为新产品导入项目领导人1.2 Agree or disagree new product can be released to manufacturing according to result of pilot run.依据试生产结果同意或不一样意新产品公布到制造阶段。 Outputl Project Charter, announce project leader ( Local NPI Project leader)s authorization and assignment Approve Project Management Planl (Scope/Time/Cost/Quality/HR/Risk, etc) Agreement while new product need bel released to manufacturing (RTM).2. NPI Project leader (Project Manager)新产品导入项目领导人（项目经理）2.1 NPI Project Leader is nominated and authorized by Management to plan, organize, lead and control Project Execution. NPI Engineer also can be NPI Project Leader when the project is comparatively small and simple. 新产品导入项目领导人由管理层提名和任命，计划、组织和控制项目标实施。假如项目较小或简单，新产品导入工程师也可成为新产品导入项目领导人2.2 NPI Project Leader will work on the Project ROI of NPT for Management justification and sign-off when needed.假如需要，新产品导入项目领导人将为新产品转移进行投资回报分析汇报，供管理层决议并签署。2.3 NPI Project Leader will develop NPI Project team with head of cross function department. 新产品导入项目领导人将和各职能部门领导一起制订和发展项目团体。2.4 NPI Project Leader will hold Project Kick-off Meeting to initiate the execution of Project. 新产品导入项目领导人将召开开启会议，开启项目。2.5 NPI Project Leader is the major communication interface of Factory to R&D (for NPD) or Outgoing Site (for NPT). 新产品导入项目领导人是关键沟通平台。对于新产品而言，工厂和研发之间；对于产品转移而言，工厂和外部工厂之间。2.6 NPI Project Leader will follow AAA NPD / NPT Standard Procedure, which is documented in Notes Database, to execute the Project 新产品导入项目领导人将依据在Notes数据库中AAA NPD/NPT标准步骤，实施项目管理。2.7 NPI Project Leader will collect and review plans for sub-task from Project Team members from cross functional department，then create schedule for NPI project. 新产品导入项目领导人将搜集和汇总各个职能部门计划，来形成新产品导入计划。2.8 NPI Project Leader will create WBS ( work breakdown structure) with team member。新产品导入项目领导人将和小组组员一起创建工作分解结构，明确职责。2.9 Establish team build plan (recognition and rewards system) for each project team.建立团体建设计划-奖励和荣誉系统。2.10 NPI Project Leader will initiate, follow-up and update the Project Master Schedule (Gantt-Chart template). Project review meeting with all team members is required on regular base (for example, once a week). In regular project review meeting, discuss project status based on weekly or monthly report from cross function, measure actual progress and compare it to planned progress, set corrective action plan immediately if it is necessary. 新产品导入项目领导人将和项目组员一起开启、遵照项目管理时间表，定时举行会议回顾和更新项目管理时间表。在例会上，讨论各职能部门提供每七天或每个月项目状态汇报，和计划进程比较来衡量实际进展，假如需要将立即提出纠正方法。2.11Submit weekly status report on weekly meeting with R&D side or outgoing facility.和研发中心或输出工厂周会上讨论每七天项目进展情况。2.12 For NPD, Project Leader will review and document each phase result with R&D side. For example: beta build, pilot run, ramp up build, etc.对于新产品项目，新产品导入项目领导人将和研发中心一起审核和归档每次生产结果：比如beta试产，小批量试产，爬坡量产。2.13 Project Leader will ensure to deliver new product to mass production on schedule with Quality Plan. Product Quality Plan should meet universal and AAA specific quality standard which is agreed with AAA R&D team and AAA Manufacturing Plant.新产品导入项目领导人将确保新产品按时按质递交到批量生产。产品质量计划应该达成一个研发和生产全部能够接收通用质量和AAA特殊标准。2.14 Submit final report/ information to GM & management for final decision of RTM.提交最终汇报或信息给总经理和管理层，作为同意正式投入生产依据。2.15 Project Leader will lead the Project Team to support successful Production Ramp-up for the 1st three months at most. And lead the NPI ramp-up review and sign-off of Mass Production Release. 新产品导入项目领导人将领导NPI团体支持最多三个月(具体期限视项目复杂程度而定)爬坡生产，并领导爬坡生产审核和签署量产生效。2.16 Project Leader will lead the NPI Closure review and submit the wrap-up report to Management. 新产品导入项目领导人将领导NPI结束审核，递交管理层综合汇报 Output Weeklyl meeting report ROI report if it is necessary- Transfer DBl WBS(l work breakdown structure) NPI schedulel Manufacturing Plan for eachl build Recognition and rewards systeml Final pilot run reportll Project closure report3. Head of cross function department各职能部门责任人3.1 Assign 1 member as internal coordinator from each function department for NPI project. He /shi is the member of NPI project team.指定一个组员作为本部门内部新产品协调人，她/她是新产品导入项目团体组员。3.2 Assist own NPI coordinator to achieve NPI sub-task on schedule.帮助本部门新产品协调人根据计划完成项目中给予任务。3.3 Set KPI (Key Performance Indicator) for NPI as commitment.设定关键绩效指标作为支持新产品导入承诺。 Output KPI (Key Performance Indicator) for NPIl Assignment for internall coordinator4. NPI Manufacturing Engineer新产品导入制造工程师4.1 Setup schedule for all manufacturing preparation task and submit it to NPI Project leader in time at project beginning. This schedule should include measurable goal for each task.在项目开始时候设定和制造准备相关任务计划时间表，提交给新产品导入领导人。这个计划时间表应该包含可衡量指标。4.2 Submit weekly report to NPI Project Leader before local weekly meeting on time, attend weekly meeting to discuss present status.在每个当地周会前按时提交进展周报，参与周会时讨论现在状态。4.3 Attend weekly meeting with R&D side出席和研发中心周会4.4 Complete DFM (Design for manufacturing) & FMEA (Failure Mode and Effect Analysis) review with R&D during alpha and beta build if it is necessary.假如可能参与alpha 和beta 生产，并和研发一起完成DFM和FMEA审核汇报4.5 Discuss with R&D on all manufacturing issues during preparation period.在准备阶段和研发讨论一切和制造相关问题。4.6 Check Primary BOM, include part attribute (make/buy, based on roll up) review, BOM structure review and BOM accuracy review. Especially after ECN, provide it to BOM maintenance person to correct attribute, and provide it to R&D to correct BOM.检验工程BOM，包含属性，结构和数量正确，尤其是ECN以后，提供给BOM维护人员修改属性，和提供研发修改错误。4.7 Get Gerber file, bare board, PCBA sample and unit sample if they are necessary,取得PCB电子文件，空线路板，样品线路板和样品整机假如必需话。4.8 Work with MEI specialist to create assembly work instruction for PCB assembly and final assembly for beta build, pilot run and ramp up build step by step, release formal assembly WI before mass production.和MEI工程师一起创建线路板和成品最终装配生产指导书，并在试生产过程中完善，最终在批量生产前正式发放。4.9 Create production line layout, process flowchart, station and labor assignment创建生产线布局，步骤图，和工作站和人员分配计划4.10Work with facility engineer, test engineer and MIS dept to complete production line layout design, setup, and prepare special tools and jigs for new product if they are necessary.和设施工程师，测试工程师和IT工程师一起完成生产线布局设计、安装。为生产线准备部分特殊工具和夹具。4.11Work with qualification engineer to verify local parts before beta build and pilot run和部品认证工程师一起在每次试生产前验证当地产部件。4.12Direct and train cell leader and operator from production dept during beta build, pilot run and ramp up run.在新产品导入期间指导和培训线长和操作人员4.13Take over responsibility to Manufacturing Engineer to in 3 months at most after pilot run.在试生产后最多三个月之内向生产部制造工程师移交全部职责。4.14Summary daily report for Ramp up创建和汇总爬坡生产每日汇报4.15 Provide label information from PLC DB.提供标签信息。4.16 Calculate & submit workload (Man hour or labor cost) before mass production, provide it to BOM maintenance person.计算工作负荷(人工小时，人工成本)，提供给BOM维护人员。4.17Complete build report after beta build, pilot run and ramp up run. Lead cross function to solve all problem.在每次试生产后提交生产问题汇报。并领导项目小组组员处理这此问题。4.18Work with platform engineer, test engineer and quality engineer to create DPU report according to quality plan in NPD/NPT DB.和产品工程师、测试工程师和品质工程师一起完成NPD/NPT数据库中品质计划。4.19Complete NPD step on time, these step include Operator training, Mfg process Audit, Pilot run Report, Mfg Stand report, etc.完成NPD数据库中要求文件和步骤，包含操作人员培训，制造步骤审核，试生产汇报，制造标准汇报等。 Outputl Schedule for all manufacturing preparation task Weekly Report forl preparation period Daily Report for build periodl Line Layoutl & Plan Reviewed BOM with correct attributel Assembly Work Instruction l MEI/WIDB Operator training planl & NPDDBrecord Labell information for unit & PCBA Cycle time and UPH reportl Workload (l Man hour, or Labor cost) NPDDB Mfg Stand report l DFM Report (l include Issue log) FMEA Reportl Beta build Report ( include Issuel log) NPDDB Pilot Run Report ( include Issue log) l Mfg Process Auditl NPDDB Ramp up daily reportl5. NPD Buyer (NPD Purchasing Coordinator)新产品采购 （新产品采购协调人）5.1 NPD planner is SCM (supply chain management) coordinator, he/she should submit material status report weekly during production preparation period, submit material status report daily during each phase production such as beta build, pilot run and ramp up run. Material status report is created according to purchasing / sourcing / transferring material status, should including delivery date, delivery plan and risk parts list with comments.新产品采购是供给链协调人，她/她应该在新产品准备期间提交每七天物料状态汇报，在每次试生产前一周起 提交天天物料状态汇报。物料汇报应该依据采购/当地化和转移物料状态产生，包含抵达日期，抵达计划，和潜在危险物料清单。5.2 Setup schedule for all purchasing items and submit it to NPI Project leader in time at project beginning. This schedule should include measurable goal- delivery plan.在项目开始前为全部采购事宜设定计划时间表，递交汇报给新产品领导人。这个计划时间表应该包含可衡量目标交货计划。5.3 Submit weekly report to NPI Project Leader & NPD planner before local weekly meeting on time during production preparation period, attend weekly meeting to discuss present status. Submit daily report to NPI Project Leader in time during each phase production such as beta build, pilot run and ramp up run.在准备阶段，需要在每个当地周会前按时向新产品领导人和计划员提交进展周报，参与周会时讨论现在状态。在试生产期间需要提交天天状态汇报。5.4 Attend weekly meeting with R&D side出席和研发中心周会5.5 Coordinate purchasing team member to update purchasing items status in material tracking sheet weekly before each phase production such as beta build, pilot run and ramp up run. From1 week before production period , need update material status daily in time协调采购团体内部，立即更新材料跟踪表格中采购部件状态。频率：每次试生产前为每七天，在试生产前一周起为天天。5.6 Create Cost table for scrapped part and rework parts after ECN implementation, lead old revision parts rework or scrap issue.在ECN实施后为报废和返工材料创建费用表格，领导旧版本物料返工和报废事宜。5.7 Check if there have zero cost material in system, make sure all cost are uploaded in system according to latest PO price or average PO price.检验系统中是否有零价格物料，确保全部在系统中价格和最终订单价格或平均价格一致。Output Schedulel for all purchasing items for beta build/ pilot run and ramp up Weeklyl Report for preparation Daily Report from 1 week ahead of each buildll Updated Material tracking sheet regularly Cost table for scrapped andl reworked parts for ECN Completed cost BOMl6. Sourcing & Qualification Coordinator部品认证 /当地化协调人6.1 Work with purchasing team and planning team to distinguish parts into “can be localized “ or “ can not be localized” according to BOM? Develop localization plan for future和采购和计划一起识别BOM中元件是否能够当地化？制订当地化计划。6.2 Setup schedule for all sourcing items and submit it to NPI Project leader in time at project beginning. This schedule should include measurable goal. sourcing plan, sample delivery/ approval plan.在项目开始前为全部部品认证 /当地化事宜设定计划时间表，递交汇报给新产品领导人。这个计划时间表应该包含可衡量目标当地化计划，样品递交和同意计划。6.3 Submit weekly report to NPI Project Leader & NPD planner before local weekly meeting on time during production preparation period, attend weekly meeting to discuss present status. Submit daily report to NPI Project Leader in time during each phase production such as beta build, pilot run and ramp up run.在准备阶段，需要在每个当地周会前按时向新产品领导人和计划员提交进展周报，参与周会时讨论现在状态。在试生产期间需要提交天天状态汇报。6.4 Attend weekly meeting with R&D side出席和研发中心周会6.5 Monitor parts release status, push R&D release all parts before pilot run.监控元件公布状态，推进研发部门在正式试生产前公布全部元件6.6 Coordinate qualification team member to update sourcing items status in material tracking sheet weekly before each phase production such as beta build, pilot run and ramp up run. During production period, need update material status daily in time.协调部品认证/当地化团体内部，立即更新材料跟踪表格中当地化部件状态。频率：每次试生产前为每七天，在试生产前一周起为天天。6.7 Coordinate qualification team member on parts verification with NPI manufacturing engineer during pilot run period. After verification, submit CTQ (critical dimension/items check list) for critical parts to Vendor Improvement department and Quality Assurance department. The check list is baseline of incoming quality check for 1st batch raw material for ramp up.协调部品认证/当地化团体内部和新产品导入工程师一起在试生产期间确定部品。在确定后，向供给商改善部门和品质确保部门关键部品关键尺寸/条目检验表。这个检验表是爬坡生产原材料进料检验依据。6.8 Develop tooling plan制订模具计划Output Sourcingl & Localization Plan Weekly Report for preparationl Daily Report from 1 week aheadl of each build Updated Material tracking sheetl Critical dimension/itemsl check list for critical parts Tooling planl7. NPD Planner新产品计划员7.1 Work with NPI Project Leader and NPD engineer to set each phase production plan during new product introduction period.和新产品项目领导人/新产品工程师一起制订每个试生产计划。7.2 Release MRS to production line and warehouse before each phase in time during new product introduction period.在每次试生产前发放物料请求清单给生产线和仓库7.3 Modify items phantom attribute after alternative(Cell)BOM copy , If it is necessary如有需要，在cell BOM 复制后修改虚拟阶属性7.4 NPD material planner is responsible to do and update material shortage report based on BOM物料计划负责制作物料需求表, 供采购提供物料交货状态7.5 NPD material planner will follow up all ECO/ECN and update it i