Phase Gate Risk-Based New Product Development uses methodologies and competencies
that bring preventative, risk management techniques into the New Product Development
process (See Figure 3). This process includes marketing/sales, continues into R&D,
then into Engineering and Manufacturing, and finally to the Supply Base.
Omnex typically works with organizations to first customize their New Product Development
(NPD) process, integrating Phase Gate Risk-Based tools into the existing processes
and the organizational structure, and redefining tasks to enable employees to understand
and fulfill their new roles. Following this, the updated NPD process, methodologies
and redefined roles and responsibilities are deployed organization-wide including
deployment to the Supply Base. Fig 3 – Risk focused Plant floor Controls (Phase
Gate Risk Based NPD) Fig
Over 20 different tools and methods are introduced with this methodology. Some of
the tools used in Manufacturing are shown in Figure 4.
This methodology − known as Advanced Product Quality Planning or APQP − employs
Failure Mode and Effects Analysis (FMEA), Measurement Systems Analysis (MSA), Statistical
Process Control (SPC), and Production Part Approval Process (PPAP). Omnex is on
the writing committee of three of these standards that helped transform the Automotive
industry, which were also used by the high tech and semiconductor industries that
are now being embraced by the Aerospace industry.
In the 1980’s, Omnex invented the linkages between Process Flow, PFMEA, Control
Plan and Work Instructions on the manufacturing floor using Product and Process
Families. This led to the implementation of these linkages in Omnex’s flagship software
application − AQuA ProTM − which is part of the EwIMSTM suite. Another Omnex accomplishment
involved Omnex principals helping Ford Motor Company transform the supply base of
its Powertrain division with the Dimensional Control Plan (FMEA and Control Plan
Omnex repeated its success by promoting and transforming the Semiconductor Industry
in the 1990s by employing the Phase Gate Risk-Based New Product Development Process.
We are currently employing this process in the Aerospace industry with the Advanced
Quality Planning process (AQP) and also with the Food Industry using the HACCP process.
Finally, Omnex has developed methodologies to integrate Quality, Environmental,
and Health and Safety including Social Responsibility using the FMEA in a methodology
called Integrated Risk.