Why do so many companies make a mess of New Product Introduction and wonder why Warranty Fail Rates are HIGH?

With complex electronics part of almost all new consumer products, especially those with wireless capability, it is becoming more difficult to ensure New Product Introduction runs smoothly and produces a High Reliability product. Most companies struggle to meet new product first shipment deadlines and focus attention on a production pilot run to weed out defects and potential issues that need to be resolved before volume production begins. As pilot production is often performed with the best sub-assemblies and components and built on a line with experienced people, many issues are simply not seen or induced during assembly compared to free flowing mass production. We cannot continue to use the excuse for high defect rates as ‘It’s a New Product!!’, and without improvement to NPI, companies will continue to THROW AWAY profit, perhaps as much as $10 million per year in a High Volume Environment. • Without NPI Metrics, people and teams do NOT work cohesively and do NOT achieve best possible performance • Metrics bring Teams Together and drive Continual Improvement • NPI Metrics allow Management to Focus on areas requiring most support and improvement, also it makes engineers jobs more defined and more structured It is clear that many mass production consumer devices are failing at higher rates than ever before, hence to reverse this situation is all about preparation and control far earlier in the development cycle.

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