SOP FOR NEW PRODUCT DEVOLOPMENT PROCESS

OBJECTIVE
New Product development

SCOPE
This standard operating procedure applicable for...........................and their Allied Suppliers to provid
Supply of Precision Springs, Wire -forms & Strips, ECN implementation.

EXCLUSIONS
Design & Development of Products & Services

RESPONSIBILITY

MANAGING DIRECTOR Provide strategic advice to the CFT team & supervise the work of
DIRECTOR & MARKET Lead the CFT team, Provide strategic advice to the CFT team &
RESERCH su
providing guidance. To provide market research & provide new
p
Ensuring availability of machine, manpower, material. Ensure
PRODUCTION HEAD
the
product.
Analyse the product requirement, vender approval , process
QA HEAD appr
suitable document to each departments. Also review of product
s
analytical method by suitable data. Update and monitor product
MR Monitoring & Asses the company policy and procedure.
STORE HEAD Arrangement of Raw material , Packing and dispatch , Vender
ma
ALL HEADS Update current status of NPD product to QA head ( project head

Procedure
New product development will be executed in phases. Each phas
sequentially based on requirements during product
development meeting with respected team member(CFT
members CFT Memb Store, Purchase, Dispatch, Tool room.
PHASE - I
The NPD team discuss the conceptually about new product devel
 Gathering necessary data focussing on Customer requirement . T
Suggestion for development of new product like Reliability and Q

Activity (Procedure) Input

Received Part Drawing / Standard

from Customer end. After
1 Part drawing / standard /
received part drawing & standard Samples
review of customer inputs &
material specification.

2 Preliminary Listing of Critical

Part Drawing / Standard
Characteristic.

List of Critical
Prepare Initial Feasibility & Risk
3 Analysis Characteristic& Drawings,
CSR

If Initial Feasibility & Risk Analysis

4 not Feasible, reply to customer for Feasibility & Risk Analysis
the same.

If Initial Feasibility & Risk Analysis

Feasible prepares Quotation,
5 discuss and take approval from Feasibility & Risk Analysis
top management and send to
customer

If required, cost negotiation and

spec. meeting (if necessary) shall
be done with the customer for
6 the same and Receive Purchase Purchase Order
Order to Customer and go ahead
for development department

Purchase Order is Feasible,

Review of Phase – I
7 Activities. Purchase Order
Phase – I Activities feedback give
to Director & market research
and review required within two
Days.

PHASE - II ( PHASE II & PHASE III product and process design and developme

Note :- Product Design activity not done in ELVEE springs.

As per product customer ( product) requirement project head (
Q Product Development Request Note (NPDRN)" Annex -xxxx .
Co fill the necessary detail. NPDRN num was initiated ABCD XXX
ZZZ Prototype Control plan was created.
PHASE - III
Production head & team shall go through the NPDRN request &
activity by confirming resources availability( Raw material,
Skilled with respective process head.
Store head develops packaging procedure and standards
QA head & team reviews the Testing samples, methods, Docume
PFMEA,Pre-launch CP, MSA plan, preliminary Process Capability
P

MICRO PLAN ACTVITY SHELL CONTAIN WITH RESPONSIBILITY M

A TOOL & DIE PREPARATION

B EQUIPMENT / MACHINE PREPARATION
C GAUGE \ INSP EQPT. PREPARATION
D ADVANCE DESIGN CHANGE INFORMATION
E LESASON LEARNT FROM PAST TROUBLE
F SPEC TEST VERIFICATION PLAN
G CTQ PARAMETERS IDENTIFICATON
H MAKING PROCESS FLOW CHART
I PROCESS FMEA VERIFICATION PLAN
J MAKING PRE LAUNCH CONTROL PLAN
K OUT SOURCING VENDER READYNESS
L LOCAL/IMPORTED RAW MATERIAL PLAN
M PACKAGING TRIAL PLAN
N CAPACITY VERIFICATION PLAN
O FLOOR PLAN LAYOUT
P CHARACTERISTICS MATRIX
Q PRELIMINAY PROCESS CAPABILITY STUDY PLAN
R MEASUREMENT SYSTEM ANALYSIS PALN
S OTHER CUSTOMER SPECIFIC …ETC.

Activity Input

Prepare Development Time line

Plan with clearly defined (Gantt
chart) responsibility of CFT Feasibility Study, Risk
8 Team and target date Analysis, Contract Review
and also prepare the , Purchase Order, CSR
responsibility matrix.
Responsibility Matrix shall explain
the Cross Function team.
 At the time of Development time Development Plan
line preparation, it shall be Resp. Matrix with CFT Team,
9 ensured that all the past problem Micro plan, Project Review
related to similar product has record.
been taken care. Development Plan

10 Prepare Listing of Gauges,

Equipment, Machines, Die Do
&Tools.

Prepare B.O.M & Part Drawing (If

Required), and get Approval if
11 required. Approved Customer input
BOM,
After Approval Issue Drawing /
Standard to Concern supplier.

PHASE-IV (Product and process Validation)

In this phase Significant production conducted During a productio

Planning Team should validate that the control plan and process
the products meet customer requirements. Additional concerns s
investigation and resolution prior to regular production runs

Activity Input

Conduct Significant Product run

(Aa per Pilot lot size / 8 Hrs) or
Customer specific. Conduct MSA
Study and Process capability
study (If Required)
Conduct internal & External
packaging evaluation Prelaunch Control Plan,
12 Prepare the production FMEA, PCS, Inspection
control plan Standard
Confirm the PFMEA
implementation results
Confirm the Spec test
Results
Conduct Layout inspection for 05
Samples Or Customer Specific.

PSW Submission to Customer with Production Control plan,

Capacity confirmation,
13 PPAP Level III or Customer Specific SPC, MSA, Spec Test
requirement. Results, Layout inspection
 After PSW Sign off with the
14 customer, Start for serial Status of targets and
production process Capability

15 And Conduct the review of quality

management system. Signed PSW

In case of any ECN raised from

customer, refer the APQP Matrix.
Review of ECN within defined
16 Working Days Or as per Customer input & Drawing
Customer Requirement after
Receiving from Customer.
Feasibility study of Change Point.

Update relevant Documents like

Control Plan SOP, Inspection
Standard. Etc if required and
17 submit to Customer & Update Old Documents
the Revision Status of documents
in Master list of documents.

PHASE-V
In this phase after PSW sign off get the feed back from customer,
continual quality improvement

Activity Input

Get feedback from customer

18 / communicate to customer Feedback report
for further action at every
phase.

When serial production starts

19 Review of targets & Monitoring of SPC Plan & SOP
Process Stability

If Completion Ok, then release

20 S.O.P, FMEA for Production All Targets
process,
 21 Review learning of Project (Things
Project review
gone wrong/things gone right)

APQP project file has been

22 completed as per the checklist APQP file
& signoff

APQP DOCUMENTS REVIEW PLAN ARE LISTED BELLOW.

A
APQP file document has been reviewed once in a year

B
Design change

C
Material or source change

D
More than 2 years since the part was produced

E
Change in process, Tool or Location.

ABBRIVATIONS

Abbreviation Expansion Abbreviation

CFT Cross Functional Team QA
ECN Engineering Change Note NPD
MKT Marketed DEV
CSR Customer Specific Requirement FMEA
PFC Process Flow Chart MSA
CP Control Plan MIS
BOM Bill Of Material PSW
PCS Process Capability Study SOP
QMS Quality Management System PPAP
MOM Minutes Of Meeting
APQP

PREPARED BY
 ISO 9001-2015

DOCU#
Rev OO
INNITIAL DATE 3/26/2019
LAST REVISION DATE -

e a service of Manufacture &

executives providing guidance.

pervise the work of executives
roduct details.
skill set related to new

oval and distribute the

pecification report by
status.

nagement.
)

es executed simultaneously or
process. ( All decisions taken by
ers:-Mkt, Dev, QA, Production,

opment ( Initial Kick-off meeting).

eam member contribute their
uality goals.

Output Responsibility

DIRECTOR
Review of Customer
& MARKET
Input
RESERCH

DIRECTOR
List of Critical
Characteristic & MARKET
RESERCH
DIRECTOR
Feasibility & Risk
Analysis & MARKET
RESERCH

DIRECTOR
Feasibility & Risk
& MARKET
Analysis Report
RESERCH

Quotation STORE HEAD

Go to Dev. Dep't. QA HEAD

Review of Phase–
I( record need) Activity QA HEAD
(MOM)

nt)

A Head ) initiate the " New

ordinate with different Dept.
shell proceed for development
labour, Equipment's, tools ets,
)

nts ( PFC, Floor plan lay out,

lan, records, reports. Gate way approval

ATRIX

Output Responsibility

Development Plan
DIRECTOR
Responsibility Matrix
& MARKET
with CFT Team,
RESERCH
Micro plan,
&CFT
Project Review record.
 Past Problem review
record (LESSON QA HEAD
LERNT)

List of Gauge,
Equipment, QA HEAD
Machines & Tools

BOM, Drawings QA HEAD

n trial run, the Product Quality

flow chart are being followed and
hould be identified for

Output Responsibility

Production Control
plan, Capacity
confirmation, SPC, MSA, Production
Spec Test Results, head
Layout inspection

QA head &
Level III PPAP Or as per production
customer requirement head
 Signed PSW QA head

QMS Review QA Team

Engineering Change Head QA &

Note production

Updated Documents QA Team

Assessment and action for

Output Responsibility

Action Plan QA HEAD

Internal assessment QA HEAD

Monitoring QA HEAD
 Monitoring QA HEAD

Head NPD QA HEAD

Expansion
Quality Assurance
New Product Development
Development
Failure Mode Effects Analysis
Measuring System Analysis
Management Information System
Part Submission Warrant
Standard Operating Procedure
Production Part Approval Process
Advanced product Quality
planning

APPROVED BY
M/s Elvee Springs Pvt ltd..Bangalore DOCU# ESPL/MVQS

NEW PRODUCT DEVELOPMENT - RFQ CHECK POINTS

1. PURPOSE
3.ToEXCLUSIONS
define the check points in detail for new product development at RFQ stage
Design & Development of Products & Services
2..SCOPE
4.Manufacture
PRE CHECK POINTS
& Supply of Precision Springs, Wire -forms & Strips - Wire
initial
Dia Applicable to allatnew
Check points time of RFQ
Products & Process, design change (ECN’s), material change, process
change, Re Process Equipment /Parameter
Machine,Check points
Layout Department
Change & Supplier Change.

3.1 RAW MATERIAL

a. Wire Size 0.15 mm - 2.50 mm Purchase
a. Type
b. Specification Purchase
b. Grade
a. In Stock
b. Exisitng Suppliers
c. Availability c. Domestic / Import a. Purchase b. Stores
d. Made to order
a. In Stock - Elvee - 0 days
c. Lead time for b. In Stock - Dealer - 7 -
procurement 10 Days c. Manufacturer a. Purchase b. Stores
- 6 - 8 weeks
3.2 MANUFACTURING PROCESS

a. Compression Spring
b. Tension Spring
c. Torsion Spring
a. Type of Spring d. Conical Spring Marketing / Sales
e. Wire forms
f. Special type

a. Coiling
b. Forming
c. Stress Releiving 1. Production 1
d. Secondary operation
b. Number of process e. End Grinding 2. Technical Team 3.
f. Finish Production 2
g. Any other
special process
 a. CNC Wire Coiling M/c
b. CNC Wire Forming M/c
c. CNC wire forming M/c
With Wire Rotation 1. Production 1
c. Type of Machine d. CNC looping Machine 2. Technical Team 3.
required e. Automatic End Grinding Production 2
Machine f.
Tempering Furnace
g. Conveyor Furnace
a. Skilled Labour Availability 1. HR department 2.
d. Man Power b. Highly Skilled Labour
availability Production 1

3.3 TOLERANCES REQUIRED

a. Compare with Tolerance Chart of Elvee

& then with Standard tolerance & inform
customer at RFQ stage if tolerance issue 1. Production 1
is there b. if 2. Technical Team 3.
a. Mentioned in Drawing certain tolerance can be achieved by Production 2 4.
additional inspection / method / process ,
this needs to accounted and informed to Quality Assurance
customer

Compare with Standard Tolerances if

given tolerances are less than Elvee 1. Production 1
Tolerance Standard tolerance reference -
b. Standard Tolerances a. Machinery`s 2. Technical Team 3.
Applicability handbook 27th edition Production 2 4.
b. IS tolerance for cold forming Quality Assurance
of springs)

1. Production 1
Check with customer & Confirm 2. Technical Team 3.
c. Missing Tolerances Tolerances.
Production 2

3.4 INSPECTION & TESTING

a. Can check with available In-
a. Dimensional & House checking aids 1. Sales / Marketing 2.
Functional Test b. Need 3rd party Quality Assurance
NABL accredited testing

b. Endurance Testing We cannot carry out in-house, 1. Sales / Marketing 2.

required Only 3rd party testing Quality Assurance

3.5 PACKAGING
Compare with Elvee Standard & 1. Sales / Marketing 2.
a. Customer Specifed Review Stores

1. Sales / Marketing 2.
b. Elvee Standard QMP 8.2.2 D/A rev 0
Stores
a. Check for material availability 1. Sales / Marketing 2.
c. Special Packing b. Cost
Stores
c. Lead time

3.6 TRANSPORTATION
 a. Surface 1. Sales / Marketing
b. Air
a. Mode c. Train 2. Stores
d Ship 3. Admin
1. Monthly 1. Sales / Marketing
2. Fort Nightly
b. Frequency c. Weekly 2. Stores
d. Kanban 3. Admin

a. Elvee Preferred 1. Sales / Marketing

c. Any preferred b. Customer Specified 2. Stores
transporter c. Location Preferred 3. Admin
a. Ex- works - Own Pick Up
b. Ex Works - Paid by customer 1. Sales / Marketing
d. Terms & Included in invoice 2. Stores
C. To Pay basis d. CIF 3. Admin
e. Any other

3.7 OTHERS
a. invoice 1. Sales / Marketing
a. Documentation b. Inspection reports 2. Stores
& Reports c. RMTC
3. Admin
d. Any other
1. Sales / Marketing
b. Any other customer 2. Stores
specific requirement if any
3. Admin

4. FEASIBILITY REPORT
QMP 8.2.2 D/B rev 0
Feasibility report for Sample development & lot manufacturing can be given seperately.

5. QUOTE PREPARATION & SUBMISSION

After precheck , quote can be submitted

Brief Summary :
1. 99% of the enquiries are standard spring enquiries which fall under our range & Scope
2. 95% of the time material is available from existing Stock
3. Once the material & scope falls into our category, again 99% of the times it can be manufactured on our mac
4. 95% of the springs are manufactured in standard tolerances
5. Special case springs are reviewed at time of RFQ & sample development and only after 100% fea
6. Once the feasibility is confirmed lead time for manufacturing is minimum 1 - 4 weeks depending on the orde

Prepared by
Pradeep Kumar P
A/D/1.1 Rev 0

meter Range - 0.15 mm - 2.50 mm

location of Plant,

Team & Responsibility

Pradeep Kumar P
Pradeep Kumar P

1. Pradeep Kumar P
2. Venkatesh Rao

1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

Pradeep kumar P

1. Prakash V
2. Pradeep Kumar P
3. Sunil Periera
4. Anand KJ
1. Prakash V
2. Pradeep Kumar P
3. Sunil Periera
4. Anand KJ

1. Pradeep Kumar P
2. Sunil Periera

1. Prakash V
2. Pradeep Kumar P
3. Sunil Periera
4. Anand
KJ 5.
Sandeep Singh

1. Prakash V
2. Pradeep Kumar P
3. Sunil Periera
4. Anand KJ
5. Sandeep Singh

1. Prakash V
2. Pradeep Kumar P
3. Sunil Periera
4. Anand KJ

1. Prakash V
2. Pradeep Kumar P
3. Sandeep
Singh
1. Prakash V
2. Pradeep Kumar P
3. Sandeep
Singh

1. Pradeep Kumar P
2. Venkatesh Rao
3. Madhu
1. Pradeep Kumar P
2. Venkatesh Rao
3. Madhu

1. Pradeep Kumar P
2. Venkatesh Rao
3. Madhu
1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P
1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

1. Pradeep Kumar P
2. Venkatesh Rao
3. Praveen P

hines

sibility confirmation for bulk production is given.

r type.

Approved by
Prakash v