Product Realization: Going from One to a Million

ISBN-13: 9781119649533 / Angielski / Twarda / 2021 / 480 str.

Anna C. Thornton

Recenzje

"Anna Thornton's book is the book we have always wanted for our hardware entrepreneurs. Most books about launching new products focus on the software and services side. A lot of the advice in those books does not translate directly to hardware entrepreneurship. Hardware is hard and teams need to learn how to work around the unique challenges of managing the transition from prototyping to mass production, and managing hardware operations with its unique cash flow challenges and impact on unit and overall economics. This book is a go-to resource for new and experienced hardware teams to help them plan for and execute a new hardware startup successfully and avoid common pitfalls. Highly recommended." --Bill Aulet, Managing Director, The Martin Trust Center for MIT Entrepreneurship, Professor of the Practice, MIT Sloan School, and Author of Disciplined Entrepreneurship"Prof. Thornton does an excellent job demystifying the process required to take a working prototype all the way through high-volume manufacturing. In her book, she sheds light on the 'unknown unknowns' of manufacturing and clearly explains each step of the journey based on her extensive first-hand experience. All companies building high-volume products should read this book." --Scott Miller, CEO Dragon Innovation"Dr. Thornton has put together nothing short of a masterpiece in Product Realization. Nearly every hardware startup founding team I've worked with is lost when moving from a prototype to full scale production. Thornton provides a tactical roadmap for how to get from here to there, profitably. Do yourself a favor and keep this book within an arm's reach as you scale!" --Erica Iannotti, Growth Strategist, Tech to Market Advisor, Serial Entrepreneur, and Founder, Manufacturing Corps & Hardware Scaleup"Product Realization picks up where so many product design books end. Prof. Thornton clearly explains what it takes to bring a product from completion of the concept development stage through the necessary steps of pilot testing, manufacturing planning, tooling design, quality management, supply chain ramp-up, and full-scale production. Here is the book that explains it all -- chock full of shop-floor wisdom, fascinating stories and compelling examples." --Steven Eppinger, Professor of Management Science and Engineering Systems, Massachusetts Institute of Technology"Taking a new product from idea to full scale production when it involves manufacturing a piece of hardware or tangible product is a complex undertaking. The advent of 3D printing and online fundraising sites, like Kickstarter, have made it easier for folks to build realistic prototypes and raise significant capital for interesting product ideas. However, as many failed startups can attest, taking those prototypes to scale and delivering it to customers are a greater challenge than most imagine. Anna Thornton's book "Product Realization: going from One to a Million," is exactly what those startups needed. She covers the process from concept to production, breaking it into key steps and provides detailed checklists, practical examples, and documents that illuminate the way to successful implementation. In reality, a product needs to not only address the user's needs but also be easy to manufacture, assemble, ship and support. This book outlines the planning processes from product design and planning to manufacturing and production planning and eventual distribution and support. It should be a must-read reference for anyone who intends to successfully build a product and bring it to market." --Desh Deshpande, Entrepreneur & Life Member of MIT Corporation"Design courses help students design and develop a great prototype. Business classes help the student to consider how the design can be profit making. And manufacturing classes help the student understand the many ways a product can be mass produced. However, there is a critical gap that a designer/entrepreneur must know that to make the leap from a single prototype to something that is actually mass producible using modern global strategies. This book fills this gap in an engaging and concrete way based on Prof. Thornton's deep experience in industry." --Maria Yang, Professor of Mechanical Engineering and Engineering Systems, MIT"Anna Thornton's Product Realization: Going from One to a Million contains the critical information and roadmap hardware entrepreneurs need as they take their concepts from prototype to production. The emergence of new prototyping tools such as 3D printers, desktop mills, and laser cutters as well as electronics such as the Arduino and Raspberry Pi has spurred on a renaissance in product entrepreneurship. Prototyping product concepts and gathering customer feedback has never been easier. Yet the knowledge required for transitioning an idea from prototype to production is scattered and rarely covered in sufficient depth. This book finally addresses that gap and is the resource product developers have been desperately lacking. I look forward to recommending Anna's book for my Product Entrepreneurship courses at Cornell and Hardware Programs at Rev: Ithaca Startup Works." --Ken Rother, Managing Director eLab and Visiting Lecturer of Management, Johnson Graduate School of Management"An excellent, practical guide for first time entrepreneurs building physical world products. Anna draws from a variety of real world situations to provide advice in a format that is easily digested and applied to a wide range of industries." --Laila Partridge, Managing Director, STANLEY+Techstars Accelerator

Spis treści

Acknowledgements xiii1 Introduction 11.1 Examples 21.2 Building Ten Thousand is Very Different from Building One 61.3 Product Realization is a Marathon 81.4 The Factory is Not a Giant 3D Printer 91.5 Three Rules 91.6 Why Learn about Product Realization? 101.7 Book Structure 12Summary and Key Takeaways 152 Are You Ready to Start? 162.1 Is Your Concept Ready? 172.2 Is the Technology Mature Enough? 202.3 Is the Prototype Mature Enough? 212.4 Is the Product Definition Mature Enough? 222.5 Is Manufacturing Mature Enough? 242.6 Is there Enough Cash and Is there Enough Time? 252.7 How Ready is Ready? 27Summary and Key Takeaways 283 Product Realization Process 293.1 Product Development Processes 303.2 Industry Standards 333.3 The Pilot Process 36Summary and Key Takeaways 524 Project Management 534.1 Roles and Responsibilities 564.2 Critical Path 634.3 Risk Management 694.4 Managing Your Enterprise Data 74Summary and Key Takeaways 795 Specifications 805.1 Integrating with the Product Development Process 835.2 Parts of the Specification Document 845.3 Gathering Information 895.4 Managing a Specifications Document 98Summary and Key Takeaways 1016 Product Definition 1026.1 Types of Parts 1056.2 Bill of Materials 1146.3 Color, Material, and Finish (CMF) 1236.4 Mechanical Drawing Package 1266.5 Electronics Design Package 1306.6 Packaging 131Summary and Key Takeaways 1377 Pilot-phase Quality Testing 1387.1 Definition of Quality 1407.2 Quality Testing 1457.3 Pilot Quality Test Plan 149Summary and Key Takeaways 1768 Costs and Cash Flow 1778.1 Terminology 1798.2 Non-recurring Engineering Costs 1838.3 Recurring Costs 1888.4 Revenue and Order Fulfillment 2038.5 Cash Flow 205Summary and Key Takeaways 2109 Manufacturing Systems 2119.1 Production System Types 2149.2 Dedicated Manufacturing Facilities 2159.3 Areas in a Manufacturing Facility 2209.4 Lean Principles 223Summary and Key Takeaways 22710 Design for Manufacturability and Design for X 22810.1 Selecting Manufacturing Processes 23010.2 Design for Manufacture 23410.3 Design for Assembly 23810.4 Design for Sustainability 24010.5 Design for Maintenance 24210.6 Design for Testing 24410.7 Design for SKU Complexity 24410.8 Eleven Basic Rules of DFX 245Summary and Key Takeaways 25111 Process Design 25211.1 Process Flow 25511.2 Manual vs. Automation 25711.3 Work Allocation to Stations 25811.4 Process Plans 25911.5 Standard Operating Procedures 26211.6 Material Handling 266Summary and Key Takeaways 26712 Tooling 26812.1 Types and Their Uses 27012.2 Tooling Strategy 27712.3 Tooling Life-cycle 28212.4 Tooling Plan 284Summary and Key Takeaways 28613 Production Quality 28713.1 Measuring Quality 28913.2 Tracking Quality 29213.3 Production Quality Test Plan 29613.4 Control Plans 303Summary and Key Takeaways 30614 Supply Chain 30714.1 Make vs. Buy 30914.2 Types of Supplier Relationships 31014.3 Owning Manufacturing or Using a CM 31414.4 Supplier Selection 31914.5 Documents 32214.6 Managing Your Supply Base 32914.7 Single vs. Dual Sourcing 33014.8 Touring a Factory 331Summary and Key Takeaways 33415 Production Planning 33515.1 Production Planning Concepts 33615.2 Forecast to Order Timeline 34315.3 Complicating Factors 34415.4 Shorter Lead Times are Better 349Summary and Key Takeaways 35016 Distribution 35116.1 Distribution Process 35316.2 Outsourcing Distribution 35816.3 Distribution System Design 359Summary and Key Takeaways 36217 Certification and Labeling 36317.1 Certifications 36417.2 Labeling and Documentation 371Summary and Key Takeaways 37718 Customer Support 37818.1 Warranty 38118.2 Recall 38318.3 Customer Support 38518.4 Customer Support Data 393Summary and Key Takeaways 39919 Mass Production 40019.1 Manufacturing Scalability 40119.2 Continual Improvement 40319.3 Cost Down 40519.4 Auditing 40819.5 Equipment Maintenance 40919.6 Launching the Next Product 41019.7 Conclusions 410Summary and Key Takeaways 411Glossary 412Acronyms 428References 431Index 438

O autorze

ANNA C. THORNTON, PhD, started her career in academia as a faculty member at MIT and then transitioned to industry for 17 years. She works with large and small companies in a wide variety of industries to transform their ideas into reality. She is now a Professor of the Practice in the Mechanical Engineering Department at Boston University where she teaches undergraduate and graduate courses in manufacturing and product realization.