New Product Development & Engineering Processmothercaregroupsourcing.com/pdfdoc/NewProductDevelopmentAnd... · Introduction This document outlines the product engineering process

New Product Engineering

& Approval Process

Page 1 of 12 New Product Development & Approval Process

Version 1 Updated: 16 October 2007

Contents Introduction Sections

1. Roles & Responsibility

2. Process overview

3. Engineering Samples

4. Certificates

5. Sealing and Approval form

6. Measuring the success of the Engineering Process

Annexes

A. Glossary of terms

B. Sample Labels

C. Approval and Sealing Form

D. Certificate Submission Form

E. Summary of Samples required during Development by other Functions



Introduction This document outlines the product engineering process applied by ELC and Mothercare in the development of own brand toys. The purpose of this process is to ensure that any toy bearing the ELC or Mothercare brand is safe, and meets our customers’ high expectations with regard to play value, quality and functionality.

1. Roles & Responsibility Product engineering and production quality are the responsibility of the supplier. It is the role of the ELC / Mothercare team to ensure that the product is engineered to a standard which meets brand standards with regard to safety and quality, and to offer guidance & support to the supplier’s engineering team. Suppliers are expected: a) To interpret our design & specification correctly taking into account:

• Current legislation • Mass production tolerances and constraints • ELC/Mothercare customers’ expectation of quality and performance • Materials

b) To consistently deliver samples and production that meets our expectations. c) To be able to make their own analyses of issues, identify potential issues and offer

recommendations and workable solutions. d) To be experts in their own area of expertise. e) To be committed to develop an engineering partnership with ELC/Mothercare focused on

developing the best product possible first time on time. f) To take the initiative - do not assume that if something has not been raised by

ELC/Mothercare, it is not important.



2. Process Overview Engineering Stage Supplier Submits ELC/Mothercare Action

Product Review Sample (PRS)

Produce product specification Generate sealing and approval form

Development & Engineering

Final Design Sample (FDS)

Review sample against product specification and advise supplier of any further modifications required

Green Seal Green Seal Sample Green Seal Certificates

Review sample & certificates to determine whether the product specification has been met. Give authorisation for production to commence production.

Gold Seal Gold Seal Samples Gold Seal certificates

Review sample & certificates. Give authorisation to ship (subject to satisfactory pre-shipment inspection)



3. Engineering Samples Sample Type Purpose

Brand

New

Off the shelf

Re-introduction

Re-vam

p

Qty of sa

mp

les required

Product Review Sample (PRS) Proposed construction (Where possible proposed materials should be used)

Risk assessment to identify any safety hazards. Produce initial specification for the performance & construction standards for the finished product. Identify any required design changes prior to design finalization. Identify requirements for:

• The inclusion of leaflets • On product labeling. • Test certificates & Doc’s

Where no PRS stage is needed, the FDS appraisal will incorporate the requirements of the PRS review.

X X X 1

Final Design Sample (FDS) Correct construction and materials (Where possible proposed colour & finish) The sample should be packed in white box (if this is not available detail of the proposed packaging materials should be given.) Heavy items requiring transit drop test must be submitted in proposed packaging at this stage for testing purposes.

To review action taken with regard to any design changes requested and finalize the design and construction of the product Review the sample against the initial construction and performance specification and finalize the performance and construction specification Carry out/review the results of any in development external testing trialing required.

Review the packaging construction and materials If engineering has not reached a stage whereby the product specification cannot be finalized, suppliers will be asked to resubmit the FDS sample

X 2



Sample Type Purpose

Brand

New

Off the shelf

Re-introduction

Re-vam

p

Qty of sa

mp

les required

Green Seal Sample Correct construction, material and colour, packed in white box Draft assembly and usage instruction (from supplier or from HK design)

Review by technologist and buying to ensure all changes have been actioned Review and sign off all instructions and leaflets Sign off product and authorize mass production

2

Gold Seal Sample Mass production samples taken from first production

Check that the item meets the standard agreed at green seal. Check packaging is in compliance with the packaging specification To verify that all safety requirements have been met and that the product specification has been met in mass production.

To provide a reference samples for inspection & for monitoring ongoing compliance.

6

NB: It should be noted that the samples listed above are the samples required by ELC/Mothercare for engineering. In addition to this, other samples are required for ranging, packaging & catalogue photography (See annex 3 for details of samples required for other processes).

Submission of Samples a) All samples should be labelled with the appropriate label (see annex A). b) At each sample stage the supplier is required to update the product development and

approval form. The updated form should be emailed to the technologist and a hard copy should be supplied with the sample.

c) Samples should be sent to:

HK managed: Product Manager UK managed: Product Technologist



4. Certificates & Declarations of Compliance a) The submission of test certificates forms part of the sealing process at green and gold

seal stages. Green Seal Tests which can be carried out pre- production as tests can

be applied to materials rather than finished product

Gold Seal Tests which must be carried out on mass production supplied at gold seal stage

Continuity Renewal Renewal of high risk standards to monitor ongoing compliance. Required annually on 1st Nov or 1st Feb. depending on product type

b) The approval and sealing form includes a submission form and highlights details of the

test certificates required at Green Seal (if required), Gold seal and for annual resubmissions

• These detail which certificates are required for the item being developed.

• Full details of the test requirements can be found in the document Test &

Technical File Requirements for Own brand Toys. A copy of this document can be obtained from www.elc.com.hk or by email from Mothercare.

c) All test certificates and declarations of compliance should be submitted with the

completed submission form in electronic format (see annex D). 5. Sealing and Approval Form a) Following receipt of the first sample the technologist will produce the sealing and

approval form for the item being developed. On review of each sample this form will be updated and issued to the supplier.

b) Prior to submitting further samples, the supplier should update the relevant sections and

the form and return it to the technologist when the next sample is submitted. See annex C see for more details.

6. Measuring the success of the Engineering Process ELC/Mothercare employs an NPD process, which on average is 9 months from concept to 1st production. It is therefore imperative that the engineering process is efficient in the identification and resolution of issues is approached in a timely manner. ELC, Mothercare and all suppliers should therefore be committed to developing product in such a way that the two key performance indicators of engineering quality are met:

1. To resolve all issues within the 4 sample stages and for there to be no iteration of any one stage.

2. No post launch modifications required to debug product.



http://www.elc.com.hk/

Annex A : Glossary of Terms Own Brand: Product in ELC/Mothercare packaging carrying the ELC or Mothercare name and address. Branded: Product in the producers own packaging carrying there name and address. HK Managed: FOB product/suppliers managed by the Hong Kong office. UK Managed: FOB or domestic suppliers managed by the UK office.

• As a rule of thumb suppliers managed by the UK are those whose design and engineering are managed outside of Asia and payment for goods is also to a non- Asian based company.

• The product development process for UK and HK managed suppliers is the same but

the buyer takes on the responsibilities of the product manager as well as fulfilling the buying role.

Own Brand Project Types Brand new: Product not yet in production. This includes product designed by ELC/Mothercare design teams, product designed by external design houses, product designed by the supplier/manufacturer. Off the shelf: Existing product already in production, usually recoloured and repacked into own brand packaging or for trial in the suppliers packaging with a view to future own branding. Re-introduction: Product that has previously been ranged that is being reintroduced into the range. Revamp: Currently ranged product that is being refreshed (recoloured &/or repackaged). Branded Product Types FOB: bought on FOB terms Domestic:: bought on domestic terms Broker: One off buy (e.g. WIGIGS, sale buys etc)



Annex B: Sample Labels

Supplier name

Submitted by

FAO (Tech Name)

Description

Age Grade SKU

Mothercare ELC

Brand (tick applicable box):

Final Design Sample Product Review Sample

Submitted by

Description

FAO (Tech Name)

Supplier Name

Age Grade SKU

Mothercare ELC


Submitted by

Description

FAO (Tech Name)

Supplier Name

Age Grade SKU

Mothercare ELC


Green Seal Sample

Supplier signature

ELC/ Mothercare Signature

Supplier name

Submitted by

Description

Age Grade SKU

Mothercare ELC


Gold Seal Sample



Annex C: Approval and Sealing Form The form is set into 3 sections as follows:

Design review - risk assessment Safety review of the product

Gives details of any modifications required. Details action taken by the supplier to resolve the issues raised.

Construction requirements – performance assessment Specifies the performance requirements for the toy

The results of reviewing the submitted sample against the specification. Gives details of any modifications required. Details action taken by the supplier to resolve the issues raised.

On product labels Gives details of any warnings or symbols which need to be applied to the toy.

Leaflets to be included in product

Gives details of any leaflets that are required to be packed with the product

Development & Engineering Results of review of PRS & PDS samples.

Test requirements Identifies at which stages certificates are required. Details of what testing is requires at which stage are given on the certificate submission forms which are supplied with the sealing and approval form.

Green Seal

Documents any unresolved issue to be corrected during production. Details action taken by the supplier to resolve the issues raised. Record of receipt of applicable certificates.

Gold seal Documents any issues found at gold seal stage. Details action taken by the supplier to resolve the issues raised. Record of receipt of applicable certificates & Doc’s



Annex D: Certificate Submission Forms Green Seal Test Certificates Testing required at green seal stage will

be highlighted. Supplier to complete cert number, issued by and date information in the table at the time of submission.

Gold seal Test Certificates Testing required at green seal stage will be highlighted. Supplier to complete cert number, issued by and date information in the table at the time of submission.

Continuity Renewal Test Certificates Testing required as continuity will be highlighted. Date for submission of renewal test certificates will be inserted. Supplier to complete cert number, issued by and date information in the table at the time of submission.

Declaration of Compliance Technologist will add the requirements to be included in the declaration of compliance. Supplier to copy and paste declaration of compliance template onto suppler headed paper and sign by appropriate company representative, with company chop where appropriate.



Annex E: Summary of Samples required in the Development by other Functions Ranging Sample Name Characteristics When Required Number

Required Range review Good representation of the design.

Colour & material need not be correct

SS 1st May AW 1st November

1 sample

Sign Off /Franchise Presentation

Visually correct (colour and print mocked up

SS 1st July AW 1st January

2 samples

Photography Sample Name Characteristics When Required Number

Required Packaging Of correct construction, and colour,

packed in white box As early as possible. Latest 2 months before first production

1 sample

Catalogue Of correct construction, and colour SS 1st October AW 1st March

1 sample

Marketing Sample Name Characteristics When Required Number

Required Press Show trade fair Pre production sample correct

material & colour in colour box (box can be mock up if necessary)

End June (required AW launch product only)

1 sample

