1. Explain the differences between EVT, DVT and PVT, or the engineering validation process.
2. Manufacturing overseas adds additional complexities and risks as geographic, communication, and cultural barriers can sabotage the product launch process.
3. This is where a New Product Introduction (NPI) team can make a substantial impact on commercializing a new product.
BUILDING THE PROTOTYPE
1. Before any testing can occur, the first step is a prototype build (also known as EP or Proto), which is essentially a low quantity (1-10 units) run combining engineering and design with the end goal of creating an MVP (Minimum Viable Product) the engineers can confidently claim is only a handful of iterations away from being mass production ready.
2. Often these prototypes are significantly more expensive than the expected production build because there are typically few cost optimizations at this stage. The prototype should provide the team with a database of parts and model files that can be sent to the Manufacturer for an RFQ (request for quote).
ENGINEERING VALIDATION TEST (EVT)
1. You’ve got a working prototype, now it’s time to start testing. With a typical run of 20-50 units, EVT (Engineering Validation Test) is when looks-like and works-like prototypes are combined to ensure all functional requirements of the PRD (product requirement document) are being met. EVT is generally the most critical gate review for electronic devices and unlike the EP, this build is done with the intended materials and manufacturing process.
2. It’s common for engineers to be present, as this is often the first time a Manufacturer is assembling the product, and up to 40% of units can fail for a variety of reasons. If any significant design flaws are uncovered after initial functional testing and analysis, there may be an EVT II build once these flaws have been addressed.
DESIGN VALIDATION TEST (DVT)
1. Now you’ve got the hardware ready and it’s time for DVT (Design Validation Test). While the goal before getting here is to have one mass production-ready configuration to test, it is common for this not to be the case.
2. DVT focuses on perfecting tools and techniques for a consistent run and ensures products meet cosmetic and environmental requirements using both mass production tools and parts.
3. With a build of 50-200, units are put through rigorous tests such as burning, dropping from certain heights, submerging in water as well as extensive battery testing. This step is also crucial for products needing regulatory certifications such as FCC or UL. This is the final step before making units that are suitable for sale.
4. At the end of DVT, you should be highly confident that any issues causing unacceptable yields have been corrected.
PRODUCTION VALIDATION TESTING (PVT)
1. This may be the most exciting stage of the engineering validation process. PVT (production validation testing) is the first official production run, often 5-10% of the first run, where teams verify that the product can be made at the volumes needed for the target cost.
2. Ideally, these units will be suitable to sell and will become part of volume ramp. It’s important to note that in PVT, your QA (quality assurance) and QC (quality control) procedures are developed which will allow the Manufacturer to check for any failures throughout the manufacturing process.
3. As products come off the line, it’s the last opportunity for adjustments to tools to be made. Once performance and quality have been verified and signed off, it’s onto mass production!
NEW PRODUCT INTRODUCTION (NPI)
1. By nature, engaging with a manufacturer is a long-term partnership and as with any relationship, it’s important to get off on the right foot. Often the difference between a good manufacturing partner and a bad one comes down to how successfully new products were launched into production.
2. Was design and engineering intent preserved? Were processes put in place and validated to ensure consistent production quality? Were business needs honored by keeping projects on time, on cost, and on scope?
3. This is where a New Product Introduction (NPI) team can make a substantial impact on commercializing a new product.
4. By nature, an NPI team “straddles the fence” between the iterative, creative development cycle and the detail-focused and process-driven world of mass production. This role depends on a familiarity with the customer's product and business needs as well as a deep understanding of a supplier’s production capabilities. A high functioning NPI engineering team will employ subject matter experts in key processes like injection molding, SMT manufacturing, die casting, and motors and drive systems.
5. Effective project management and communication are equally important. International manufacturing can be a minefield of organizational issues, and it takes extra diligence to overcome gaps in language, time zones, and visibility. When you’re trying to meet an aggressive project schedule it’s no time to play the telephone game.
6. Beyond strong professional skills, doing business in Asia depends on good cultural sensitivity and forging strong relationships. Again, this is where an experienced NPI team can pay huge dividends. There is no substitute for time spent on-site, and most NPI resources will have considerable direct experience working hand-in-hand with key partners overseas. These links provide a strong continuum of engineering and project management support across the globe and throughout the product launch process.
7. Often the most limited resource for NPI projects is time, and it’s very common for the launch schedule to be compressed due to development delays or an acceleration of demand. When considering timelines for product launches, the best results come when the combined project team starts with accurate and detailed deliverables and follows a clearly defined process.
8. Manufacturing is driven by details, and it is common at the onset of a project to lose time “filling in the blanks” in documentation. This is where a home-based team is so helpful, as they will understand a supplier’s requirements around BOMs, 2D and 3D product data, PCBA data, artwork, etc. A local team can save valuable time by working to identify and resolve missing information and incorporate documentation best practices before this data enters the international feedback loop.
9. Similarly, much time can be lost by the iterative process of working to resolve DFM feedback. Even the best developed products need changes before being ready for production, and it’s common for development teams to not budget time for revisions after submission to a contract manufacturer. Even if the schedule is tight, it is worth the effort to resolve these issues quickly and effectively to prevent further delays down the road.
PROCESS DRIVES INTERNATIONAL COLLABORATION
1. Established processes cut through language and time barriers and help keep the collective team aligned. A typical NPI process centers around five key activities:
2. Project planning – Even simple NPI projects benefit from robust planning, and unfortunately this is often the most overlooked step in the product launch process. An effective project kickoff will define the scope of work, establish project management expectations, and identify key risks and mitigation plans. Post-COVID supply chain constraints demand that teams immediately identify and begin procurement of key long lead time materials.
3. Product optimization – Domestic and international engineering teams work with customers to optimize the product design to capture critical-to-quality characteristics and to bring the product within production capabilities. Product testing needs are identified and planned, and production process documentation is crafted.
4. Tooling construction and trials – The NPI team develops tooling designs with suppliers to ensure engineering intent is maintained. When necessary, the team will review parting line, ejector pin and gate locations (PEG layouts) on injection molding and die casting with the customer for approval. Our electrical engineering teams will also work to define PCBA testing requirements and will work with our offshore test engineering team to develop production test fixtures. Often the domestic NPI team will travel overseas to assist with first trials of new tooling and to work to optimize the assembly and testing processes with our suppliers.
5. PPAP sampling and submission – Engineers will follow a production part approval process and review production-representative samples and supporting process control documentation with the customer.
6. Product launch readiness – Project managers will work with our production and supply chain teams to finalize materials and arrangements for first production. Engineering will supervise and review first production samples and quality inspections.
7. In the end, it takes a strong relationship, a globally distributed team, well established processes, and hard work to launch a new product into mass production. When the time comes to select a partner to bring your new product to market it’s important to make sure they have what it takes to ensure the project is successful!
Source:
https://news.ewmfg.com/blog/npi_team_is_critical
https://news.ewmfg.com/blog/evt-dvt-pvt-explained
