New Product Introduction (NPI)

What is New Product Introduction (NPI)?

We make complex sheet metal fabrication projects simple for our partners. That starts with our unique New Product Introduction (NPI) service. New Product Introduction is the process of taking a product concept from an idea or design through the develop phase to full scale manufacturing. It means understanding and developing a customer’s product in a controlled and structured environment prior to serial production.

There are numerous benefits to NPI, including reduced development costs through improved engineering design, reduced manufacturing risk, and quicker product to market timelines.

Putting your product through our NPI process will allow you to see and understand all the steps needed to take it from prototype stage to serial manufacture. We can review and advise on the functionality of the product against design and flag any specifications which might prove unachievable or financially restrictive.

Our NPI process is highly cross functional, involving close collaboration between engineering, quality, and production teams. This collaboration ensures that every aspect of the manufacturing process is considered and optimised well before scaled production begins.

Taking your product through NPI helps with a controlled release into scaled production. It also lets our team understand your labour and space needs. This way, we can provide accurate lead times and quotes and ensure your business planning is based on real, data-driven forecasts.

NPI can also be invaluable for the onboarding of existing products in partnership with OEMs (Original Equipment Manufacturers).

Contact us to discuss how New Product Introduction could benefit your project, or read on to learn more.

Why is New Product Introduction (NPI) important?

Executing a robust NPI process can be the difference between success and failure for a business. Our customers recognise the critical role that NPI plays in the serial production of complex metal fabrication, and why we have a dedicated NPI facility and team consisting of the very best in class sheet metalworkers and fabricators. These experts not only possess deep technical expertise, but also a true passion for better that is unrivalled.

The entire Universal Wolf NPI department is driven and managed by a dedicated project team whose responsibility it is to check on every aspect of a project. The different phases of new product introduction are controlled by approval gates which ensure the project has met specific criteria before moving onto the next phase. The Universal Wolf NPI team have the authority to allow a project to move forward, but more importantly to stop, evaluate, and revise when necessary.

What are the advantages of NPI?

Whether you are an OEM (Original Equipment Manufacturer) or a technology disrupter in your industry, the importance of implementing a robust NPI process has proven to be a key competitive differentiator for our customers.  We believe that once a product has entered production, there should be zero issues.

We believe that without a strong and dedicated NPI process, a project put directly into production may face issues. For example, it might be hard to bend a product because serial production needs specific tools or press brake tonnage. Also, the product’s design might have flaws.

The advantages of a vigorous new product introduction process, include:

1. Reduced development costs: By collaborating with our customers in the early stages of the NPI process, our design team can avoid late design changes, revisions, and costly validation testing
2. Faster time to market: With a reduction in development time, the product reaches market and begins to generate a return faster
3. Improved product quality: The Universal Wolf NPI process is focused on ensuring the product meets our customers’ needs and that the outcome results in producing a consistent, repeatable, quality product
4. More efficient manufacturing: Through the effective use of Design for Manufacturing best practices, our customers’ products are designed with serial production in mind

The Universal Wolf NPI Process

Understand (Design for Manufacturing)

Even before our NPI process begins, we will collaborate with our customers to understand their product and contribute our Design for Manufacturing expertise; designing accurate, production-ready drawings ready for manufacture.

Design for Manufacturing is completed with a handover meeting from our technical sales team to a dedicated NPI project team.

Phase 1: Define 

During the Define phase, our project team will conduct an in-depth review of the data and information supplied by our customers. This phase involves a review of technical specifications and drawings, and sets out all needs and outcomes. The outputs of this phase include a defined scope, risks, suppliers, validated drawing pack / specification set, and agreed Critical To Quality components.

Value add: Reduced development cost through early collaboration.

Phase 2: Prepare 

Prepare is the first “doing” phase. We conduct CAD/CAM, determine space, equipment and site mapping, to get the NPI cell ready for manufacture. We design jigs, fixtures and agree the schedule with customers. The Prepare phase outputs includes CAD/CAM drawings, sign-off by customer and run sheets.

Value Add: Faster time to market through reduced development time.

Phase 3: Execute 

The Execute phase involves the manufacture of a sample product. It is focused on moving the product from design into a defined form, while assessing any risk. Outputs include a validated product sample, drawing pack, bill of materials, specifications and operating procedures, bill of materials, weld qualifications and quality plan.

Value Add: Improved product quality through the development of a consistent, repeatable process.

Phase 4: Validate

The Validate phase is generally initiated following production launch, and provides the project team an opportunity to tie up any remaining documentation tasks, review process performance and collect customer feedback. This is the project team’s opportunity to review lessons-learned and document them for use in future projects, a key differentiator for Universal Wolf as we continue to develop a robust and industry-leading NPI process.

NPI for existing products

Although more commonly associated with new-to-market products, New Product Introduction is also beneficial for Original Equipment Manufacturers, when switching from an existing to a new supplier.

Manage your risk 

Onboarding a product via NPI helps to manage the risks associated with bringing a new product on board, by releasing your product into production in a controlled way. This allows us to understand drawing packs, Critical to Quality requirements, and ensure all documentation is in place.

Optimise for repeatable manufacture 

Switching supplier presents an ideal opportunity to review your technical drawings. Our Engineering team are experts in Design for Manufacturing, and can make sure your drawings and specs are optimised for efficient and repeatable manufacture.

Manufacturing technology is always changing, which allows us to streamline even further – for example, it could allow us to change the approach to a particular manufactured element to remove cost and time in production.

The Pack Approach

At Universal Wolf, we recognise the role that New Product Introduction (NPI) plays in the manufacture of high-end metal fabrication. That’s why we created our dedicated NPI department. Our NPI team are best in class sheet metalwork and fabrication engineers who have deep technical knowledge and a passion for better that is unrivalled across our competition.

Our NPI department has been recognised as a game changer for our industry with one customer telling us they’re “not aware of any other manufacturers investing in NPI on this scale outside the automotive industry”.

Tools of the Trade

• A member of the NPI team can take part in initial discussions to clarify if a project will require input from the NPI department
• Customers will have a nominated Project Manager and NPI representative who will maintain regular contact with the customer
• The NPI department will guide the release into manufacture ensuring a smooth transition
  The NPI department can highlight any quality processes that must be followed
• The NPI department can formalise the scope of the project
• The NPI department will be responsible for managing all technical aspects of the product review and adoption

To talk to us about how we can support you with NPI, get in touch.