Jom tengok contoh aliran kerja (workflow) seorang NPI Engineer dari peringkat idea produk sehingga ke mass production.
📌 Workflow NPI Engineer
1. Design Stage (R&D / Engineering)
- Review design awal → pastikan Design for Manufacturability (DFM) & Design for Assembly (DFA).
- Semak BOM (Bill of Materials) & drawing.
- Beri feedback kepada design engineer tentang potensi masalah di production.
2. Proto Build Stage (Prototype / Engineering Build)
- Bekerjasama dengan R&D menghasilkan prototaip.
- Semak fit, form, function (FFF) → pastikan design boleh dibuat & berfungsi.
- Uji material & proses asas.
- Buat initial risk assessment (FMEA).
3. Pilot Build Stage (Pre-Production Run)
- Menyediakan process flow, work instructions, dan control plan.
- Setup line kecil (pilot line).
- Laksanakan DOE (Design of Experiment) untuk validasi proses.
- Jalankan reliability & compliance test (drop test, thermal cycling, vibration, dll).
- Kenalpasti isu yield/defect awal → lakukan corrective action.
4. Qualification Stage (Process Validation)
- Proses melalui OQ/PQ (Operational Qualification / Process Qualification).
- Gunakan PPAP (Production Part Approval Process) atau dokumentasi setara.
- Sahkan jigs, fixtures & mesin stabil.
- Pastikan supplier juga validasi material & komponen.
5. Ramp-up Stage
- Peralihan daripada pilot line kepada mass production line.
- Monitor yield, cycle time, takt time.
- Buat line balancing dan optimasi proses.
- Train operator & technician.
6. Mass Production Stage
- Pastikan proses stabil sebelum handover penuh kepada Production team.
- Pantau first lots untuk kes konsistensi.
- Lengkapkan dokumentasi → WI, SOP, lessons learned.
- Jadi point of contact jika ada isu design vs production.
📊 Ringkasnya:
- Awal → banyak koordinasi dengan R&D & supplier.
- Pertengahan → banyak uji proses, setup line, troubleshoot.
- Akhir → handover kepada production dengan dokumentasi lengkap.
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