42629 lecture 3 pt2
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The document discusses integrated product development (IPD) and presents an IPD model. It uses a case study of developing a new pouring closure for glass bottles to illustrate how the IPD process works. The case study outlines gathering market information, generating ideas, evaluating concept alternatives, and selecting a final concept to develop. The goal was finding a solution that was cheaper and easier to produce while providing market differentiation through new functionality.
42629 lecture 3 pt2
- 1. Integrated Product Development Integrated Product Development Process Thomas J. Howard https://sites.google.com/site/thomasjameshowardhomepage/ thow@mek.dtu.dk Unless otherwise stated, this material is under a Creative Commons 3.0 Attribution–Share-Alike licence and can be freely modified, used and redistributed but only under the same licence and if including the following statement: “Original material by Thomas J. Howard for course 42629 – Innovation and Product Development Department of Mechanical Engineering, The Technical University of Denmark”
- 2. The three Key disciplines of Integrated Product Development (IPD) Market Product Business Production 2 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 3. The IPD model 3 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 4. Purposes, uses and limitations of the IPD model Purposes: The model will help you to understand IPD and will help you interpret progress and in NPD projects as well past projects Use: The model can be used as a checklist to identify the relative position of a project and any phases that may have been left out Limitations: The model will not tell you what to do next or which phases are most important to consider But mainly... it helps you an IPD mindset! 4 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 5. Case Study This case study will help you to relate the IPD model to a real situation It is also give you some idea of the type of documentation produced during a real development project (SLIDES WITH GREEN TITLES) 5 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 6. Setting the scene 6 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 7. Thank you to Crown Packaging for case study material !
- 8. Project Brief Follow your integrated Product Development Process throughout this brief to understand how the development project is structure. 8 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 9. Team Members • Jerry Stimpson Closures Business • Jason Hegarty Closures Business • Brian Sequeira Closures Business Brainstorm team: • Chris Smith CT closures • Keith West CT closures • Chris Ramsey Innovation CT • Henry Ellis-Paul Innovation CT • Alexandre Paris Innovation CT • Thomas Howard Innovation CT 9 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 10. Mission statement “To produce an add-on component to enable a drizzle pouring function.” 10 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 11. Competitive advantage • Shape and functional differentiation. Unique with metal closure. • Salad dressing, marinades, sauces, honey, maple syrup closure with integral pourer (note that this is already on the oil or vinegar market). 11 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 12. Project approval • Issue 2 • Date ****** • Project number 824 765 0899 5300 • Customer Companies like Craft and Nestle. • Brands Companies like Netto and Irma • Business contact Jason Hegarty • BI Ian Bucklow • CT team Thomas Howard (Project Lead) Chris Ramsey 12 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 13. Background - Objective •High interests have been elicited from customers like Craft and Nestle for an integrated pourer for the packs using metal closures. •It would allow them to offer a product with much more functionality while keeping their current capping facilities. 13 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 14. Existing oil/vinegar pourers 14 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 15. Market info • Products Salad dressings, honey, maple syrup, Asian sauces, chilli sauce… • Existing packaging Glass bottle with 43mm 38mm and 30mm Twist Off closures: – 43mm: RTO, RTB – 38mm: Regular RTB, RTP, medium MTB, MTP, deep DTB, DTP – 30mm: MTP, MTB, MTO – Pasteurisable compound – Tamper evidence shrink sleeve, tag, button – Decoration Decorated cap, sleeve – Serving size from sprinkle to pour. – Serving time Serving time variable. • Other packaging on market Glass and plastic bottles with/without integral pourers, metal &plastic caps, ROPP aluminium closures with insert. ***** is the only customer using insert in glass with a metal closure. • Market location launched in the UK, applicable to Europe • Outlets Supermarkets • Current market size 5-10 M p.a. ( between the 3 sizes / more 38mm than 30mm) 15 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 16. 30 MTO 16 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 17. Launch info • Target market +XMpa from plastic injection moulding in glass (also potential large increase from plastic on plastic market if adaptable) • Target additional cost ~£XX/1000 increase on existing closure. Current 38 deep sold at ~£YY/1000. < 30-40% increase on existing closure. • Target launch Short term solution (6-8months): insert pushed in / longer term solution (few years): pourer integrated in cap. 17 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 18. Musts • Easy and obvious to open and use. • Unique, giving brand differentiation. • Drip free pouring. • Suits existing capping line with minimal changes (line speed 40-300 cpm). Small m/c to fit between filler and capper. 400N capping load. • Shelf stable for 2-3 years max. • Suits hot filling 85degC max. • Clean • Able to hold low vacuum. • Adaptable to a range of viscosities • Recyclable. • Organoleptic and alimentary approval – no effect from tainting or scalping. • No changes to the glass finish • Premium look (keep current high image of metal cap on glass). • Be customisable – flexible design. • Comply with current and future food contact regulations 18 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 19. Desirables • Require no extra processes on the filling line for longer term solution. • Principle could be applied across a range of closures. • Patentable. • Suits steam flushing filling to pull vacuum. • Consumer can vary flow rate in a controlled way. • Integral TE 19 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 20. Project plan Idea phase • Brief • Research • Brainstorm • Ideas • Review meeting • Gate End October 2008 Concept phase (skipped if we select just one concept at Idea gate) • CAD design • FEA modelling & trials • Models & consumer sales research • Manufacturing routes & costs • Concept gate (select 1 concept) Supplier selection 20 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 21. Project plan Feasibility phase • Customer approval • Design for manufacture • Pilot tooling • Tooling iterations • Working prototype Development phase • ROI & Customer funding • Production tool • Customer approval • Launch END OF BRIEF 21 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 22. Design work from the ideas phase to the concept phase Thank you to Crown Packaging for case study material !
- 23. Rejected Solutions • Restrictive aperture for controlled flow of product. • Air hole to create smoother flow. • Uses existing cap and it totally concealed. – Messy due to dripping. – Insecure housing. 23 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 24. Rejected Solutions • Air tube for smoother pouring. • Premium, sophisticated appearance. • An addition rather than an integrated solution. – Gives an unfamiliar brand image. – Difficult to position on product. – Expensive. 24 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 25. Rejected Solutions • Spring loaded, retractable spout. • Air flow tube for smoother pouring. • Concealed beneath product packaging. – Too many components. – Too expensive. 25 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 26. Concept Alternatives... 26 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 27. Channelled Aperture • Post filling insertion. • Channelled aperture for a controlled flow. • Non drip rim. 27 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 28. Centre Spout • Uses existing cap. • Post filling insertion. • Channelled aperture for a controlled flow. • Non drip rim. 28 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 29. Insertion options 1 Pre-fill – Inserted in the bottle before filling. 2 Post-fill – Inserted into the bottle after filling. 3 During capping – Inserted in cap and engaged into bottle during capping. Syrup Caps 3 Bottles 1 Filling 2 Capping Distribution 29 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 30. Flexible star • Deeper metal cap • Flexible lips allowing pre-filling insertion. • Angled aperture for controlled flow. • Non Drip pouring spout. • 1 Point pouring. 30 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 31. Extended Spout •Post filling insertion. •Multi angle pouring. •Premium look spout. •Non drip rim. 31 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 32. Extended Spout 32 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 33. Two Piece • Both parts placed in cap, insertion during capping. • Holding rim remains in cap after its removal. • Non drip pouring rim. • Concealed beneath cap. 33 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 34. Break Away • Single part placed in cap and is inserted during capping. • Holding bridges break away when inserting into cap. • Non drip pouring rim. • Concealed beneath cap. 34 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 35. Break Away • Single part placed in cap and is inserted during capping. • Holding bridges break away when inserting into cap. • Non drip pouring rim. • Concealed beneath cap. 35 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 36. Folding Arms • Deep cap • In-cap solution, inserted during capping. • Non drip pouring rim. • Concealed beneath cap. 36 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 37. Folding Arms • Deep cap • In-cap solution, inserted during capping. • Non drip pouring rim. • Concealed beneath cap. 37 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 38. Plastic rim • Attached to cap and engaged during capping. • Push-over notch to secure in position. • Large centre spout (non drip). • Plastic rim exposed on exterior. • Option to remove complete closure. 38 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 39. Plastic rim • Attached to cap and engaged during capping. • Push-over notch to secure in position. • Large centre spout (non drip). • Plastic rim exposed on exterior. • Option to remove complete closure. 39 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 40. Selection Criteria 40 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 41. END OF CASE 41 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 42. Where did the value lie? No market differentiation or wow factor $$$$ Lighter, more sturdy, cheaper, better functioning product $ Cheaper, quicker and easier production $ 42 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 43. Where did the value lie? Less market differentiation $ $ Less functionality and convinience product Cheaper, quicker and easier production $$$$ 43 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
- 44. Questions ? 44 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark