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Chapter 6
Getting Ready for Production

Excerpt

Now that the design is complete, our attention turns to production. Of course, during the design phase we already emphasized production. The design that has been completed consists of:

The product (geometry and material to achieve function)

The production capability (including process engineering)

The field-support capability

During the design phase, the product has been designed for producibility, the production processes have been chosen (at least for critical part features), and the production tooling design has been almost completed, lagging the product design only slightly. This is a huge advance over the obsolete serial style of development, which would only start considerations relative to production during this production preparation phase, after the product design was supposedly complete. This led to the major problems of cash drain 7 (here's the product; where's the factory?). One of our main objectives is to overcome these obsolete dysfunctions. Now we have tremendous improvements: a robust product design, responsive to the customers, with economical tolerances embedded in the selected production processes. In this production preparation phase we put our new design into production while overcoming cash drains 8 and 9:

• Cash drain 8: We've always made it this way

• Cash drain 9: Inspection

Cash drain 8 is overcome by QFD for production and by process parameter design, the optimization of the robustness of the most critical production processes. Cash drain 9 is overcome by on-line quality control.

  • System Verification—Demonstrating Robustness
  • Building Prototypes—Design into Hardware
  • Debug Prototypes
  • System Verification Test (SVT)—Beat the Benchmark
  • Demonstrate Superior Robustness
  • Progress Check
  • Getting Ready
  • Correcting Design Mistakes
  • Developing Production Capability
  • Progress Check
  • Pilot Production
  • Organization
  • Making the Factory Floor Responsive to Customers
  • Process Validation
  • Final Test
  • Progress Check
  • World-Class Product
  • 23 Steps for the Successful Production Preparation Phase—A Summary

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