An example of a generic product development design review flow chart and checklist are presented below. The flow chart provides insight into the sequence of reviews that typically occur during the design phase. It can be an effective tool for tracking critical design parameters and producibility progress throughout this phase. The chart can be tailored, based on the complexity of the product that is under development. For hardware that is highly complex, additional design reviews may be required for better progress tracking.
- System Requirements Phase
- Clarify customer requirements
- Identify safety and environmental design requirements
- Develop conceptual design
- Identify new technology
- Establish Design-to-Cost (DTC) goals
- Establish Six Sigma goals
- Identify test requirements
- Identify key suppliers
- Identify fabrication process and capability
- Identify risk
- Hold Systems Requirements Review (SRR)
Entry Criteria: This phase begins when there is a signed contract, a budget has been approved, and the project has been staffed to support initial planning activities.
Exit Criteria: This phase is complete when the customer agrees that the requirements have been documented clearly, the goals and objective have been identified, and the conceptual design is complete.
- Preliminary Design Phase
- Identify critical design parameters
- Fabricate product model
- Develop manufacturing process plan
- Develop product test strategy
- Identify parts and materials
- Perform initial Sigma analysis
- Perform initial Design for Assembly (DFA) analysis
- Establish Defects per Unit (DPU) goal
- Update DTC goals
- Perform trade studies
- Perform preliminary producibility analysis
- Generate design documentation
- Hold supplier producibility reviews
- Hold Preliminary Design Review (PDR)
Entry Criteria: The customer agrees with the design concept. All action items from the SRR are closed.
Exit Criteria: The customer agrees with the qualification plan. Preliminary analysis indicates that the product requirements, cost, and schedule can be met.
- Critical Design Phase
- Build engineering prototype
- Verify performance to customer requirements
- Verify parametric sigma performance
- Verify process sigma to goal
- Verify DTC to goal
- Verify DPU to goal
- Final production layout
- Release formal design documentation
- Update DFA analysis
- Update producibility analysis
- Hold supplier producibility review
- Hold Critical Design Review (CDR)
Entry Criteria: Action items from the PDR are complete. The customer agrees with the outcome of the PDR.
Exit Criteria: The engineering prototype has demonstrated functional compliance to customer requirements and manufacturing targets. Final configuration has been documented.
- Production Readiness Phase
- Build pilot production units
- Validate DPU, DFA analyses to goal
- Validate DTC analyses to goal
- Validate process sigma to goal
- Optimize producibility implementation
- Generate manufacturing metrics
- Verify shipping, packaging, and customer documentation
- Certify production process
- Qualify product performance to customer requirements
- Hold Production Readiness Review (PRR)
Entry Criteria: All the action items of the CDR are complete. The customer agrees with the qualification test results.
Exit Criteria: The production process has demonstrated the capability to meet producibility and product cost targets. Parametric qualification tests have been complete and are compliant with the customer requirements. The production line is certified.
- Full Scale Production
- Ensure continuous improvement of producibility factors
- Ensure continuous measurement of the manufacturing process
- Generate design process postmortem report
- Update lessons learned list
- Periodically verify product to customer requirements
Continuously measure the process and make improvements. Perform a postmortem to improve the product development process for future applications.
- The design review process can be tailored to meet the needs of any contract and any customer. The tailoring process can be done by the IPT based on the expected output and the needs of the customer.
- It is essential that the process is fully supported by the IPT and outside expertise who will provide a variety of views on the product development progress.
- It is important that all the actions of a given design phase be complete prior to starting the next design phase.
- The postmortem process is important to provide a continuous improvement action both for the product producibility process and the product development process.
A typical design review checklist, with responsible parties and their roles highlighted for each task, is shown in Figure E.17.