Example of Tollgate-Based Project Management Template
from Industry
Chart supplied by Terry Russell, OU ME Advisory Board Chairman
ME471, Dr. Kremer
Tollgate
Project Management
Process:
• Define tollgates and checklist items to be completed for each
tollgate
• Project reviews are based on checklist items at each tollgate
Example Discussion:
The example on the next page shows a 10-tollgate template.
• The number of tollgates used can be changed.
• For this example items 1-6 correspond to “ Defining the problem and
Formulating solutions”, plus numerous project management tasks.
• Tollgates 7, 8 and 9 correspond to “detailed design and development”
• Tollgate 10 covers field support, a very important component of a
real-world product development project
GE Aircraft Engines
GE GP7000
GE GP7000
Idea Strategize Get Consensus
Feedback Propose - Prepare Launch Design Develop Validate
Produce & Support
Key Elements
Key Elements
20% 40% 70% 95% 100%10
9
8
7
6
4
3
2
1
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%5
Mission: Develop and certify by December 1999 the GE-P&W Engine Alliance
GP7000 engine for the 747-600 airplane with airplane certification by December
2000 to satisfy our customers and shareholders with world class products and
+ Need identified for NPI Process. + Establish Senior
Leadership Team. + Identify Leadership
Team. + Establish NPI Team. + Evaluate business
impact. + Define initial program
requirements. + Conceptual designs
evaluated. + Tollgate 1 checklist
review completed.
+ Define key technical requirements. + Brainstorm issues. + Develop risk
assessment criteria. + Hold conceptual
design & program cross functional reviews. + Finalize alternative approaches (strategy). + Identify manufacturing approaches. + Perform risk assessment. + Selling price established, target cost reviewed, current capability cost defined. + Prepare prelim. program plan. + Tollgate 2 checklist review completed. + Expand team membership. + Begin risk abatement
plans. + Generate preliminary
approach. + Obtain stakeholder
feedback and revise approach as required. + Vendor partners
identified. + Identify installation
impacts. + Customer study deck
complete. + Engine operability &
deterioration requirements defined. + Detailed maintenance
cost rolled up. + Airframer acceptance of
design. + Confirm all technologies
on hand. + Review Tollgate 3
checklist. + Conduct Tollgate 3
review.
+ Establish program launch scenario. + Communicate status of
program direction. + Define detailed customer
requirements. + Initiate QFD to identify
top-level CTQ’s. + Prepare detailed program
plans. + Baseline configuration
frozen. + Commercial engine
aircraft system specs completed and signed. + Approve plan to close target cost/current cost gap.
+ Tollgate 4 checklist review completed.
+ Tech Reqmnts issued. + Performance stack up
complete. + ICD approved. + Quote deck delivered. + Preliminary Type Board
held. + CERT/QUAL plan
reviewed. + Block test configuration
defined. + Program funding finalized. + Update integrated program
master plans/Identify critical path elements. + Configuration Mgt. plan frozen. + Finalize make/buy decisions. + Finalize manufacturing processes. + Identify design review &
program scorecards review schedules. + Identify Review Tollgate 6
checklist. + Conduct Tollgate 6 review.
+ Launch program. + Refine critical path
elements/schedule. + Identify CTQ’s. + Initiate concurrent
detail design & manufacturing process planning. + Hold detailed design
reviews. + Finalize detail design/test definition. + Review Tollgate 7 checklist. + Conduct Tollgate 7 review. + Procure/manufacture hardware. + Validate process capability. + Finalize detailed
cert/qual test plans. + Prepare test hardware. + Review Tollgate 8
checklist. + Conduct Tollgate 8
review.
+ Complete component tests, engine, and flight testing as required. + Confirm all program
requirements are met, and complete documentation. + Obtain customer/agency approval. + Review Tollgate 9 checklist. + Conduct Tollgate 9 review.
Prepare detailed plan
+ Finalize technical requirements. + Update business and
technical plans. Business plan approved by business council. + Identify NPI Scorecard
metrics. + Establish launch
requirements. + Confirm funding,
participants, and facilities available. + Sources selected &
approved by source board. + Cycle, flowpath &
configuration frozen, cycle audited. + Nacelle & fan reverser
supplier specs issued. + Revenue sharing
participant agreements finalized and plans completed. + Process capability
(Cp/Cpk) known for all CTQs. + Configuration Mgt system defined. + UG Master Model components selected. + Tollgate 5 checklist review completed. Launch Tollgate Completion Schedule
Percent Overall NPI Program Complete Percent Tollgate Checklist Items Complete + Review producibility data. + Review field data. + Identify ongoing
improvements. + Hold periodic Tollgate 10
reviews.
