NPI engagement, phase by phase
Kickoff — Roadmap and baseline study (save 22 weeks)
- Organization and PM operation understanding
- Roadmap discussion
- Review documents for each stage
- Supply chain strategy discussion and contract manufacturer (CM) audit
- RFP & RFQ collections and study
Risks neutralized: incorrect key component strategy (+8w), inefficient communication with suppliers (+4w), unrealistic timeline estimation (+10w).
EVT — Early risk exposure and root cause analysis (save 17 weeks)
- Enhance iteration quality (not just quantity)
- Validate test methodology readiness
- Verify root cause closure, not workaround
- Join DFM & CTQ processes
- Provide solutions for certification failure
Risks neutralized: poor test plan and sample request (+4w), lack of measurable key specifications (+2w), long lead-time for critical components (+2w), repeated HW/FW integration failures (+6w), lack of FAI of mockup (+3w).
DVT — It's not too late for everything (save 15 weeks)
- Re-source failing suppliers (capability audit)
- Drive feasible redesigns (impact-ranked)
- Recover BOM cost (targeted value engineering)
- Close documentation & execution gaps (DFMEA / ECN)
- Call for EVT reopen (gate review)
Risks neutralized: lack of standardized test procedures (+4w), cosmetic and material issues (+3w), FAI failure debate with CM and supplier (+2w), design changes driving cost increase (+6w).
PVT — What's done is done, but we still have work to do (save 9 weeks)
- Harden line capability via fixture, SOP, and cycle-time review
- Install in-line testing targeting real failure modes
- Stabilize yield across shifts via TQM at the CM
- Deliver honest PPAP — Cp/Cpk, FAI, MSA backed by data
Risks neutralized: immature or missing fixtures (+2w), lack of a golden sample as criteria (+1w), low first-pass yield because PFMEA was not included (+4w), test failure due to old-version material (+2w).
MP — Catch drift before it becomes disaster (save 8 weeks)
- Monitor quality drift via SPC on critical CTQs
- Close the field return loop via 8D and RMA analysis
- Govern ECN and VAVE via lessons learned
- De-risk single sources via dual-source validation
- Decide cost-down trade-offs via total cost review
Risks neutralized: alternate parts not fully validated (+2w), component EOL without notice (+4w), inaccurate demand forecasting (+2w).