5 Key Factors For A Successful New Product Launch

New product launches are complicated.  Often there are complex information details yet to be determined while also planning for a successful launch.  Ambiguity and last minute changes in forecasts, design and marketing content can negatively affect both the product quality and on-time delivery.

While launching a wide variety of new products, I have found the following 5 factors useful in combating the complex challenges inherent in new product launches.

    1. Communication – it is essential to create an open dialog about the goals of the launch. Understanding topics including commercialization and customization need to be fleshed out, since this will affect costs, manufacturing processes and on-time delivery.  Additionally, managing expectations through asking appropriate questions, providing explicit feed back and expressing concerns about how different choices impact launch goals, is necessary.
    2. Flexibility – launches are dynamic, and flexibility is required to negotiate all the necessary changes involved from concept to completion.
    3. Scalability – The ability to create and design systems for the many possible configurations of the product’s specifications and quantities is mandatory.
    4. Detailed Specifications – After negotiating all the change in the planning process, it is absolutely necessary to clarify the final processing specifications. Both establishing and communicating the finalized, written specifications through out the supply chain ensures that a high quality part is created.
    5. Execution – Coordinating, validating and improvising provides the basis for a successful new product launch.

Instituting these 5 factors doesn’t remove the complexities of a new product launch, but it simplifies the process and helps me and my management team maintain our sanity!

What complexities have been most challenging for you and how did you overcome them?

Achieve Target Price and Earn Profits Too!

Whether launching a new product or expanding capabilities to accommodate our clients growing needs, meeting the target price is a significant barrier to earning new revenue streams and potential profits. Sometimes we take on new business opportunities as a way to gain market share, deepen relationships or to gain an advantage over the competition. While these strategies for new business serve their purposes well, it remains essential not only to meet the target price, but also to be profitable at the target price.

Fortunately, approaching target price challenges from both a design improvement and process improvement perspective allows us to open ourselves to a path toward meeting our objectives. A design and process improvement course can make taking risks less emotional and bring us into the realm of rational decision making. What if a design and process improvement method was consistently employed, and the data collected from these efforts demonstrated that a 10%, 15% or even 30% gain in profitability is likely.

One step in achieving a data driven decision-making model is to create processes that deliver reliable data needed to incorporate into an existing decision making and forecasting model. A process that generates and delivers this kind of information is presented below. It is an iterative process that synergizes with a well known Six Sigma concept, Define, Measure, Analyze, Improve, Control (DMAIC).

Step One: Define Base Process

  • Define base process
  • Create value stream map
  • Delineate sub-processes and assign cycle times to each
  • Identify and document opportunities for improvement
  • Present per product price and improvement opportunities

Step Two: Perform Project, Provide performance Feedback and Improvement Opportunities

  • Actual cycle times
  • Yield reporting
  • Constraint analysis
  • Feasibility study
    • Incorporate actual data to engineer design for manufacturability model
    • Material & equipment suitability
    • Yield and process time optimization

Step Three: Adopt New Process

  • Define new process
  • Create new value stream map
  • Delineate sub-processes and assign cycle times to each
  • Identify and document opportunities for improvement
  • Present per product price and improvement opportunities

Step Four: Perform New Process, Provide performance Feedback and Improvement Opportunities

  • Actual cycle times
  • Yield reporting
  • Constraint analysis
  • Feasibility study
    • Incorporate actual data to engineer design for manufacturability model
    • Material & equipment suitability
    • Yield and process time optimization

This iterative process continues to deepen, creating an improvement perspective and can continue until all potential waste is removed, or can be finished when a desired target price and profit is met.  The data gathered from the process can then be integrated into our decision-making models.

While the decision-making model currently in use may not be well structured and documented, we are making decisions and are therefore using some sort of model. Enhancing our awareness regarding how we go about making decisions and adding a rational perspective to our new business strategies can support our efforts to increase revenues and profits.

Click Here to download a case study supporting this model.

Click Here to begin a conversation on how ASAP can help meet your target price initiatives.

Product Packaging: What Is The Impact Of Design For Manufacturability?

DesignWhen designing for manufacturability one of the perceived downfalls is an increase in the cost of materials required for the design.  Consider a master carton.  Various designs of a master carton with similar dimensions, flute, and paperweight specifications have separate manufacturing costs.  One design may require more board and another may require a more complicated die cut. Often design is viewed from a minimization of board and die cutting, leading to a cost only perspective.

However, designing from a cost only perspective can present down-stream manufacturing problems including:

  • Product protection
  • Transportation costs
  • Extra handling

These manufacturing issues can actually increase product costs resulting from product damage, increased transportation costs and increased labor costs.  Imagine if the design required an increase in material cost, but decreased extra handling.

Design Option
Material Cost
Labor Cost
Total Cost
Low Cost Perspective
$4
$12
$16
Design for Manufacturability
$5
$9
$14

On the surface these numbers look inconsequential.  However, this graph below illustrates the saving achieved when designing your packaging for manufacturability.

Designing product packaging is not always easy.  Time horizons continue shrinking as the push for lead-time reduction and quick product launches is ever present in today’s dynamic economy.  However, the opportunity for return on investment makes it clear that manufacturability is a concept that must be incorporated into our design processes.

Do Lean Manufacturing Principles Apply to New Product Launches?

Yes, yes and yes, lean manufacturing principles do apply to new product launches. In our journey to launch new products, how many times have we faced one or more of the seven wastes identified in Lean Manufacturing such as:

  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Overproduction
  • Over Processing
  • Defects

An obvious waste to discuss in a new product launch situation is overproduction. A typical definition of overproduction is to produce products in excess of customer demand.

Often in a new product launch, orders for the new product are created from an anticipatory perspective with the use of forecasts instead of live customer orders. Using anticipated demand systems and structures increases the opportunity for over production because forecasting demand is frequently ambiguous. We can engage in rigorous research efforts and still have errors in our calculations, add into the equation volitile demand, inflexible manufacturing systems and supply chains, and it becomes clear why overproduction regularly occurs in new product launches.

Interestingly, both the goals of a new product launch and the goals of a lean factory are striking similar. For example, in a new product launch, the desired outcome is to get our products to market as quickly, efficiently and cost effectively as possible. Like wise, the goal of Lean is to reduce cycle times, eliminate waste and reduce total costs.

Incorporating lean strategies in new product launches has many benefits including:

  • Reduced total costs by eliminating over production
  • Accelerated time-to-market by reducing lead times
  • Meeting emerging customer needs by reducing process cycle times

The launch is a crucial stage in the product development process. Applying Lean principles to this stage can create tremendous opportunities to maximize returns on our new product development efforts.

What have your experiences been with lean launch strategies and methods?

Trust, But Validate All Product Packaging Components

Validating all product packaging material is a critical step to ensure our product launches occur on time and within budget. Imagine, successfully navigating a very long and rigorous new product launch process only to discover, the launch is delayed by several weeks simply because the packaging material, such as a master carton, was not validated.

Something as seemingly simple as the correct sized master carton can have a major impact on meeting launch dates and anticipated profit margins. For example, a carton purchased that is too small for the product leaves us with a few options.

  1. Find an online resource that specializes in, in stock, off the shelf cartons and purchase the closest match to the dimensions and weight restrictions of the product. If necessary buy a larger box than required and fill the void with packing paper, print and apply carton labels, getting the product to market a few days later than planned.
  2. Change the carton drawing with the corrugate supplier, augment the printing and cutting die, and wait another 2 weeks to receive cartons, launching the product at least 2 weeks later than planned.

The first option gets the product to market sooner, but has several extra costs involved, affecting targeted profit margins. The second option can delay the launch by 2 to 4 weeks, depending on supplier lead times and our own product processing times and manufacturing schedules.

With both options, there are extra costs involved, including:

  • the extra cost per carton
  • the cost to return, destroy or inventory the wrong sized carton
  • the cost to augment or produce a new cutting and printing die
  • the cost to order the correct carton
  • the cost to print and apply a carton label
  • the cost to purchase and insert packing paper

To avoid these and other more, intangible costs validate all product packaging material before purchasing and launching new products.

 

Meeting Critical New Product Launch Dates

Bringing a new product to market is a storied journey with many roadblocks along the path from ideation to product launch. As the launch date approaches, more and more resources are invested. Meeting critical launch dates becomes increasingly important in achieving revenue and return on investment objectives.

There are many important factors to consider when planning for critical launch dates. One of those factors includes lead times. Lead times are especially significant when working within complex distribution channels and supply chains.

Lead times are a confusing and difficult issue because the definition of lead time tends to vary from supplier to supplier. The variation in definition stems from whether or not process times and transit times are included within the definition. Within the context of supply chain management, lead time is measured from the point of order initiation to the receipt of the product. However, some suppliers may only include process time.

When planning to achieve critical launch dates it is important to understand important components within lead times including, process time, transit time, receipt time and set up time.

  • Process time is referred to the total time it takes to complete an order.
  • Transit time is the amount of time a product spends traveling from supplier to customer.
  • Receipt time is the amount of time it takes to inspect and enter the product into inventory.
  • Set up time is the amount of time needed to prepare the product for the next process.

Incorporating these elements into the planning process helps us to ask better questions regarding timing, and deepens our understanding of how to enhance planning strategies for product launches.

Lead times play a critical role in meeting launch dates. Understanding the intricacies and interdependencies of each component encompassed within lead times is helpful in bringing products to market in a timely fashion, and meeting ROI objectives.

Creating New Product Launch Teams and Partnerships

New product launches require great commitment, coordination and communication among and across a diverse cross section of specialized skills.  Developing teams and partnerships to navigate the complexities inherent in new product launches becomes increasingly important as demand for speed to market increases while resources to facilitate speed decrease.

There are several factors to consider when building collaborative relationships leading to high performing product launch teams.  Some of these characteristics include:

• Trust:  Working with people you can trust creates an open environment where honest dialog regarding product and market needs are expressed.  Communicating in this manner is efficient and facilitates planning, problem solving and systems development.

• Experience:  People experienced in new product launches understand the complexities inherent in new product launches, enabling an anticipatory perspective.  Often, experience and learning from the last launch is incorporated into the next launch avoiding problematic constraints.

• Expertise:  Specific knowledge in areas such as the product, markets, channels, engineering, manufacturing and organizational systems are great resources to have on your team.  Understanding the strengths and weaknesses of specific technical areas is helpful in over coming problems by leveraging strengths and engaging other options where needed.

• Flexibility:  New product launches are dynamic and evolve as new information is learned, presented and incorporated into launch plans.  People who understand the iterative process can remain open-minded and malleable with out being attached to any one plan or one way to approach a problem.  Remaining agile in a new product launch helps keep the launch moving forward in a dynamic environment.

New product launches are demanding. Beginner, practitioner or expert, it is easy to feel engulfed by an impending new product launch. Having great teams and partnerships working in unison makes all the difference.

 

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