From idea to in-market, fast, predictable,
and right the first time.
We turn concepts into manufacturable, compliant, margin-positive products. Clear gates, tight controls, real accountability.
Why NPI with Us
Our NPI Framework
Each gate delivers tangible outputs and a go/no-go decision
What’s Included
1. PRD & Requirements
Clear, testable criteria with traceability.
2. DFM Report
Risks, simplifications, and cost-down opportunities by sub-assembly.
3. BOM & Costing
Rev-controlled BOM, target vs. should-cost, value-engineering log.
4. Prototype Plan & Reports
Design/proto cycles with pass/fail summaries.
5. Validation Pack
Test methods, standards matrix, labeling/packaging specs.
6. Production Readiness
Tooling plan, WIs, control plan, training checklist.
7. Launch Toolkit
Ramp KPI dashboard, ECN/PCN process, supplier readiness status.
8. Post-Launch Pack
PLR deck, CAPA tracker, VAVE pipeline, Rev-B/C roadmap.
Built-In Quality & Compliance
Quality is embedded at every gate, design reviews, incoming/in-process controls, and final checks. Where product type requires, we perform FQC with 100% functional and leak testing to ensure every unit works as intended. Retailer and regulatory compliance are mapped early and verified before launch.
Who This Is Tailored For
How We De-Risk Your Launch
1. Early manufacturability and cost discipline (no “surprise” BOMs).
2. Supplier enablement and line training before scale.
3. Clear acceptance criteria and gate reviews to avoid late churn.
4. Packaging, labeling, and logistics are integrated before POs.
5. Real-time ramp KPIs to keep yield and OTIF on track.
6. Data-driven VAVE and controlled ECNs post-launch to improve cost and reliability.
FAQ
Yes. We begin at Gate 1, shape the PRD, and move to Gate 2 once feasibility is proven.
Yes. We run a rapid DFM + gap assessment, then enter at the right gate.
Ours. We validate true throughput and yield on production-equivalent equipment.
Through a strict ECN protocol tied to cost, schedule, and quality impact—extended into Gate 6 for controlled iteration.
Gate 1
Ideation & Conceptualization
- Goal: Align on market need, user value, and business case.
- Key Work: Voice of customer, competitive scan, feasibility check, early cost envelope.
- Outputs: PRD/brief v1.0, feasibility note, high-level BOM & target cost, draft schedule & risks.
- Gate Criteria: Problem–solution fit, business case validated, budget/targets approved.
Gate 2
Design & Prototyping
- Goal: Prove the concept is manufacturable.
- Key Work: Architecture & DFM up front, supplier scouting, iterative prototypes, risk planning & test methods.
- Outputs: Prototype builds, design verification notes, should-cost updates, proto build plan.
- Gate Criteria: Core functions demonstrated, major risks retired, path to validation agreed.
Gate 3
Testing & Validation
- Goal: Verify the design meets requirements across variability.
- Key Work: Material/process windows, reliability & life testing, safety/pre-compliance, packaging tests.
- Outputs: Validation report, refined control plan draft, labeling/packaging spec, updated PRD.
- Gate Criteria: Requirements met over tolerance, packaging validated, tooling & process plans approved.
Gate 4
Pilot Production
- Goal: Prove the line can build it—repeatedly.
- Key Work: Pilot on production-equivalent equipment, yield tuning, work instructions, operator training, supplier readiness docs.
- Outputs: Pilot build report, golden samples, process capability snapshot (CTQs), final control plan.
- Gate Criteria: Target yield achieved, CTQs stable, readiness to launch confirmed.
Gate 5
Full-Scale Launch
- Goal: Ship at quality, speed, and cost.
- Key Work: Ramp plan, inline checks, FQC with 100% functional/leak testing where applicable, field feedback loop, ECN protocol.
- Outputs: Run-at-rate confirmation, cost lock, post-launch dashboard, customer acceptance assets.
- Gate Criteria: Sustained yield/OTIF, cost locked, lessons-learned closed.
Gate 6
Post-Launch Iteration
- Goal: Improve product and unit economics using real-world data—without disrupting supply.
- Key Work: VOC & return analysis, CAPA, VAVE cost-downs, packaging/logistics optimization, sustainability upgrades, new variant planning.
- Outputs: Quarterly Post-Launch Review (PLR), ECN/PCN log, updated risk register, VAVE pipeline with quantified savings, updated BOM/WIs, Rev-B/C roadmap..
- Gate Criteria: Quality/reliability KPIs hold or improve, validated cost-down targets achieved, change impacts assessed and approved, supply chain ready for next release.
