Integrated Product and Process Development
An Interactive, Self-administered Video Series
NCAT is currently offering a 12-module video series on IPPD as a training tool for industry and government. This series is currently being used by the US Navy as part of the DoD Acquisition Reform effort to train government program managers. The series consists of 12 video modules, each approximately 50 minutes in length with a copy of presentation materials, and a workbook with questions sections for each module topic. The presentors have been chosen from academia, industry, or government organizations based upon their expertise in particular methods or tools.
This Video Series introduces a generic methodology on how to use the Integrated Product and Process Development (IPPD) management process and provides tool application exercises. Current case studies will provide real-world implementation examples. The objective of the series is to: (1) show participants how the IPPD process can produce affordable systems that satisfy the customer’s need in less time, and (2) provide knowledge of and experience in using tools that support the IPPD process. Upon completion of these videos and the workbook exercises, each participant should understand the fundamentals of implementing an IPPD program using integrated product teams, problem definition and evaluation methods, activity based process tools, and robust design methods for variation reduction during design.
Integrated Product and Process Development is a management methodology that incorporates a systematic approach to the early integration and concurrent application of all the disciplines that play a crucial part throughout the life cycle of a system. This process seeks to use multi-disciplinary teams to optimize the design, manufacture and support of a system through the application of quality and system engineering tools and utilizing industry best practices. In May 1995, Secretary of Defense Perry directed the implementation of IPPD throughout the DoD acquisition process. A DoD Guide to IPPD was drafted in January of 1996 and various departments of the DoD have written IPPD requirements into contracts and RFPs. Industry and academia have been developing IPPD tools and practicing Concurrent Engineering (CE) methods since 1990 in order to reduce cycle time and improve quality. The life cycle cost has proven to decrease steadily with more emphasis on quality through customer focus and robust design. Georgia Tech has been developing and teaching Concurrent Engineering and IPPD tools as part of design since 1990, and NCAT has been leading the use of IPPD for Affordability through workshops and white papers. NCAT and Georgia Tech, together with Texas Instruments expertise in Six Sigma Methods, are able to combine industry and academic experience to present lessons learned and characterize the barriers to effective implementation of IPPD.
This video series presently consist of 12 modules, with plans to add several more each year. The first two modules describe the benefits and desired decision flow of IPPD and presents a generic development methodology. The subsequent modules explain individual tools within this methodology, with three implementation case studies.
Why IPPD is Important
This module presents the viewpoints of DoD leaders concerning the implementation of IPPD as a part of Acquisition and Science & Technology. This message charges program managers to utilize IPPD methods whenever possible and to be involved as customers.
Introduction to an IPPD Methodology
Dr. Daniel Schrage from Georgia Tech describes the desired system development cycle as compared to a traditional serial process. A generic methodology is introduced to attain the goals of IPPD, and the individual methods and tools are then briefed.
Seven Management & Planning Tools
Mark Gordon from NCAT starts the methodology with a new definition of the problem using Mizuno’s Seven Management and Planning Tools. These creative team tools first capture all aspects of the problem and then rank and organize the solution for improved decision making. Exercise included.
Quality Function Deployment (QFD)
In a continuation of defining the problem, Mark Gordon explains the purpose of QFD followed by a detailed guide to constructing and evaluating a QFD Matrix. This tool directly relates customer desires to design characteristics that include manufacture and support issues. The result is a ranked list of criteria for trade-offs. Exercise included.
Robust Design Methods
Dr. Daniel Schrage continues his presentation with a summation of robust design methods, including rational and intended benefits. Particular tools cover Taguchi PDOM, DOE, and Robust Design Simulation.
Six Sigma Quality Process
Ron Randall explains the Six Sigma Quality process from his many years experience at Texas Instruments. Six sigma is a formal method of variation reduction using statistical measures for evaluating Process Capability. Exercise included.
Teaming: Building A Learning Organization
Dr. Mistree from Georgia Tech conducts a very interactive session to improve teamworking skills for IPT Members. Five steps for building an organization and System Archetypes are described with advice for fixing typical team problems.
Creating an IPPD Computing Infrastructure
Dr. Mark Hale from Georgia Tech describes the many requirements of an IPPD computing environment. The integrating and cycle time reductions realized from digital modeling force different computer structures, and Dr. Hale defines these structures while providing checklists for building your resources.
Case Study: Next Generation Soldier
Patrick Snow from the US Army and Susan Pasternack from Motorola share the IPPD process followed on their Advanced Technology Demonstration. The particular tools are described along with the lessons learned.
Case Study: New Attack Submarine
Kevin Poitras from Electric Boat details the IPPD process that EB has implemented in order to dramatically lower costs and speed the development process. Extensive solid modeling with process simulation has enabled most of the cost savings and has resulted in a totally different manufacturing process.
Earned Value and Activity Based Costing
Dr. Webster from IMDT and Dr. Bras from Georgia Tech describe in turn the benefits secured from using Activity Based Costing. Accurate overhead and precise process trades offs and possible only when the process is modeled and costed correctly. Earned Value can be implemented with an ABC model in order to correctly manage cost, performance, and schedule.
Case Study: Low Cost IFOG
Persis Elwood from the US Air Force presents the continuous improvement process that was followed to produce a ten time reduction in manufacturing cost of Fiber Optic Gyros. QFD and Six Sigma methods were used for variation reduction. Innovative partnering management was also successful.
A videotape with a short description of each of the modules is available for anyone interested in purchasing the series. Each series contains the twelve video modules, (approximately 10 hours of video), presentation material, and a workbook with questions, exercises, and answers.
The introductory price for these modules is $200 each, or $1100 for the series.
Contact NCAT by email or phone: (202) 371-8451.
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