NPD 12-Step Process Flowchart

Systematic Execution

How We Develop New Parts (NPD Framework)

An interactive, APQP-aligned engineering architecture delivering First Article Inspection (FAI) right first time.

NPD APQP Architecture • ISO 9001:2015 Live Route

Approved Gate Concurrent Action Quality Check

01. Process Design & Feasibility Study

Raw material selection • Casting feasibility • Process routing

CFT GATEWAY REVIEW

02. CFT Multi-Disciplinary Meeting & Risk Review

Cross-functional team alignment (Design, Tooling, Quality, Production) • Tolerance stack-up analysis

OK → Proceed to Plan Not OK → Revisit / Modify Process

DEVELOPMENT TIME PLAN

03. Development Time Plan & Customer Sync

Weekly milestone tracking • Customer milestone lock • Resource allocation

CONCURRENT 3-TRACK ENGINEERING

TRACK A • CAM

04. CNC Programming & Tooling

4-Axis toolpath generation, specialized insert selection, cycle time optimization & collision simulation.

TRACK B • TOOLING

05. Fixture Design & Build

Custom hydraulic/rotary clamping fixtures, CMM holding nests, and precision Go/No-Go gauges.

TRACK C • APQP

06. FMEA & Control Plan

Process failure mode analysis, critical characteristics (CC/SC) matrix, and in-process inspection plans.

PROVING & METROLOGY CONVERGENCE

FIRST CUT

07. Part Proving & Machining

First workpiece setup on 4-Axis HMC, spindle load test, and dimensional dry-run validation.

METROLOGY LAB

08. Sample Part 100% Inspection

Full layout inspection on Mahr 2D Micro gauge, surface roughness check, and balloon drawing creation.

CUSTOMER VALIDATION & SERIAL HANDOVER

CUSTOMER CLEARANCE

09. FAI Submission to Customer

First Article Inspection report submission with material test certificates (MTC) and customer approval.

SERIAL PRODUCTION

10. Pilot Batch & Production Handover

Process capability Cpk > 1.67 confirmation and official sign-off for repeatable series manufacturing.

STAGE 01 SELECTED

Process Design & Engineering Feasibility

Click any stage above to inspect APQP protocol

Input Requirements

2D/3D CAD Models (STEP/IGES), Customer Drawing Tolerances, Material Spec (SG Iron / Steel).

Key Deliverable Artifacts

Process Routing Sheet, Tooling Feasibility Sign-off, Initial Cycle Time Estimation.

Quality Gate & Exit Criteria

Engineering Feasibility Approval by Chief Manufacturing Officer & QA Lead.