NPI stands for New Product Introduction, and it encompasses the entire product development journey from an idea or a concept all the way through mass production and shipment.
As an electronics manufacturer, we live in the NPI phase. People often say, "hardware is hard," and they are referring specifically to this NPI phase. NPI really is a series of hundreds of decisions of increasing complexity and consequence, and it's our job to help guide you through that process.
We have a philosophy: slow as smooth, smooth as fast, which helps guide decision-making. It focuses on making decisions in the right sequence and understanding the impact of each decision. This philosophy helps avoid unforced errors or unnecessarily risky choices.
NPI Phase 1: Create a Roadmap
In this first phase of the NPI process, we create a roadmap by asking key questions:
- What are your project goals?
- Is there a launch date that must be hit?
- What’s your target price for success?
- What markets will the product serve (US, international)?
- What certifications are required?
After evaluating the answers:
- We assess if the schedule is realistic and if the budget is achievable.
- We make risk-reward trade-offs to shorten lead time or reduce cost, potentially.
Once all the questions are answered, we create a timeline, outline our commitments, and set expectations for what we need from you as a partner.
NPI Phase 2: Engineering, Prototyping & Design for Manufacturing
This is where the rubber meets the road. All disciplines are engaged:
- Engineering, industrial design, mechanical, electrical, and firmware development.
- Overall architecture is developed, schematics designed, BOM (bill of materials) captured.
In this phase, we evaluate the design for manufacturability, ensuring the product meets functional, cosmetic, and regulatory requirements established earlier. The ultimate goal is a product that fulfills customer and regulatory requirements.
NPI Phase 3: Production Preparation & Supply Chain Setup
Here we scale up to volume production:
- After tooling, creating work instructions, and setting up the supply chain, we break the phase into three sections: EVT, DVT, and PVT.
EVT (Engineering Validation Test):
- The first production assembly. We build a small number of units and learn about bottlenecks, difficulties, or necessary changes to fixtures.
DVT (Design Validation Test):
- We run mass-production intent processes, assembling 50 to 300 units. These are used for customer-required tests like drop testing or certifications.
PVT (Production Verification Test):
- Significant mass production (1,000–2,000 units) to finalize production. By the end of PVT, we’re ready for full production unless there are surprises.
NPI Phase 4: Mass Production
- We enter full production, focusing on efficiency and quality. Our team identifies ways to improve assembly processes, shorten programming/testing time, and enhance product quality based on statistical data.
NPI Phase 5: Production & Supply Chain Optimization
- Our team starts optimizing production processes for better efficiency, faster throughput, and lower costs. We may renegotiate with suppliers for better terms based on higher production volumes.
NPI Phase 6: Logistics & Distribution Support
- We ensure that products are packaged and labeled correctly for global distribution, complying with all shipping regulations and codes (HTS codes, etc.). We assist in moving the product from the factory floor to the port for air or ocean freight, ensuring smooth delivery wherever needed.
