From Research Prototype to Production

1. From Research Prototype to Production Felix Sanchez Project Management for ARA Engineers and Scientists

2. Desired Learning Objectives • Recognize what preplanning is required to take a product from Research to Prototype Item to Production Item • Understand and appreciate the time required to complete the checklist of items that must be considered in taking a Prototype to Production using VERTEK Division: • General items • Operational • Maintenance • System specification issues • Data requirements • Ecological and Disposability • Economic and cost considerations • Facility requirements • Training • Software • Safety reviews

3. From Research to Product • General Items • Is there a real need, and what size is it? • Are we using the “most appropriate” technology? • How many suppliers are available for critical technology items? • What are the risks and uncertainties? • What are the integrated system considerations?

4. From Research to Product • Operational Item Considerations • Has the product’s mission been defined? • Have the performance requirements been defined? • What are the technical performance measures? • What is the projected life cycle? • What are the environmental requirements in the following areas? • Thermal, Humidity, Shock, Noise • Storage, in stock and field • Transportation and handling • Have reliability requirements been established? • Installations procedures (who does)? • What are serviceability requirements?

5. From Research to Product • Maintenance Item Considerations • Have the maintenance levels been defined? • What are the organizational responsibilities for maintenance? • Test and support equipment requirements? • Software for diagnostics available? • What are the spare part requirements? • What are the repair/re-supply time requirements?

6. From Research to Product • System Specifications Available? • Have specifications been established? • Are there any conflicting specifications? • Materials • Performance • Power • Operability • Safety requirements • Reliability (including test and built in test) • Maintainability • Transport • Environmental • System integration (compatibility) • Optional items

7. From Research to Product • Data Requirements – does product documentation exist, including: • Circuit diagrams • Drawing package • Manuals • Training materials • Logistical support documents • Technical support documents • Bills of materials • Assembly instructions • QA test procedures and review lists • Are records required and are they subject to audit?

8. From Research to Product • Ecological and Disposability Considerations • Are any harmful materials present? • Are special procedures required at various points in life cycle? • Are transportation requirements established? • Labels required?

9. From Research to Product • Economic Considerations • Estimated material costs available? • Estimated pricing complete? • Market analysis/marketing plan complete? • Have all costs been considered over life cycle? • Variable • Fixed • Escalation • Shipping • Learning curves

10. From Research to Product • Facility Requirements Defined? • Operational • Tooling • Maintenance • Test • Training • Storage

11. From Research to Product • Training • Have operational and maintenance personnel requirements been defined? • Have training programs been established? • Is equipment required for training?

12. From Research to Product • Software • Have software requirements been defined? • Has software been documented? • Licensing considerations? • Has software been tested and verified on operational units? • Is maintenance software required? • Safety Review • Have all product reviews been conducted and documented? • Have all facility reviews been conducted and documented?

13. Prototype to Production • Engineering Team develops and builds a prototype that meets a set of specifications mandated by the customer • Engineering delivers the prototype to the Production Team. They also provide: • Rough Bill of Materials (BOM) with vendor information (i.e. what has to be procured?) • All schematics (hardware, boards, etc.)

14. Prototype to Production Process • VERTEK Engineering and Production Teams conduct kick-off meeting to begin technology transfer and documentation process, including final Bill of Materials and drawings • At VERTEK, the Program Manager is in charge of both Prototype development and production of final product • The PM assigns a Task PM who is in charge of developing and building the Prototype • The Task PM (AKA: Technical Lead, Task Lead, Control Account Manager) • Has budgetary and technical responsibility for the R&D effort that ends in prototype delivery and acceptance by the customer

15. Prototype to Production • Prototype is considered the baseline product • All changes made from this point forward are completed via an approved Engineering Change Request/Engineering Change Notice (ECR/ECN) process • Both the PM and Technical Lead must sign off on all ECRs and ECNs • The PM evaluates ECR impact to overall program (cost, schedule, fleet configuration) • Technical Lead evaluates ECR for technical impact to product and assures product continues to meet technical specifications

16. Prototype to Production • Production evaluates prototype for: • Manufacturability • Vendor’s qualified • Scheduling production run • Personnel requirements • Equipment/Fabrication requirements • ID QC points along production

17. Prototype to Production • Procurement of components begins and Work Orders are released • PM and Team Leader validate vendor products • QA Department performs incoming inspection of key vendor parts (PCB, power supplies, etc.) • All manufacturing, electrical, fabrication and final assembly is completed • Final QA is performed • Product is prepared for shipment

18. Wrong Way to Do It

19. Right Way to Do It

20. Summary • Thorough preplanning is required to take a product from Research to Prototype Item to Production Item • You must engage VERTEK Division early – before the proposal phase – to ensure a great product for customer and ARA VERTEK staff always available for your consultation