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Product Design & Innovation
Medical Devices Summit – Colorado Springs 2012




Nina Kohnen

Director Operational Excellence,
Design Excellence
Agenda


                  Importance of Achieving Success in Innovation
                  & Product Leadership

                  A Roadmap for Success




2 |   12/3/2012
About Covidien
                                     • Global manufacturer of medical devices and
                                       pharmaceuticals
                                     • 43,000 employees with 51 manufacturing
                                       facilities located i 18 countries
                                       f iliti l      t d in       ti
                                     • 2012 Sales – $11.9 Billion
   Medical Supplies
Nursing Care, SharpSafety,
 Medical Surgical, OEM
         Surgical

                             15%

                         17%


                                   68%         Medical Devices
                                            Endomechanical, Energy,
    Pharmaceuticals                            Soft Tissue Repair,
Specialty Pharmaceuticals,                    Airway & Ventilation,
   Contrast Products,                        Oximetry & Monitoring,
 Radiopharmaceuticals,
        p                                           Vascular
  Active Pharmaceutical
        Ingredients

  3 | 12/3/2012
Achieving Market Leadership
                                            “Best Product”

                             Innovation / Product Leadership
                                                           Apple, Google, Intel, Nike, 3M




Wal-Mart, FedEx, Southwest, Dell                              Airborne Express, Home Depot, IBM
 Operational Excellence                                          Customer Intimacy
Best Total Cost, Ease of Use                                     “Best Total Solution”
Convenience,
Convenience etc
Source: The Discipline of Market Leaders- Michael Treacy

 4 | 12/3/2012
There is no Shortage of Advice on How to do it Right

  Bring clarity and certainty
      through analysis



       Reduce complexity by
        focusing on process
               design


       Take larger strides to
        a e a ge st des
       speed up the pace of
          improvement


      Fix execution to
   accelerate improvement




 5 |   12/3/2012
What is Innovation?




6 |   12/3/2012
This is one of very few 7 stars hotel in the world
It was built in only 18 months...
And opened its doors in 2003.....




  8 | 12/3/2012
9 |   12/3/2012
10 | 12/3/2012
What About These Innovations?
• Apple vs. Rest
• DVD vs. Streaming Video
• Mobile Phones vs. Landlines
• E-mail vs. Snail Mail
• Paper Maps vs. GPS




11 | 12/3/2012
My Take on Innovation

      • Innovation is the Ability to Invent, Commercialize and Expand a
         Product or Service Along a Customer’s Dimension of Value.
                                    Customer s


        –        Invention Requires a System to Generate, Prioritize & Process Ideas
        –        Commercialization Requires a Robust Product Development
                 Process to Launch Ideas
        –        Expansion Requires a System to Fully Manage & Exploit Post
                 Launch Utilization of the New Products or Services




12 | 12/3/2012
Why is Innovation Important?

     • Innovation is the Only Competitive Advantage a Company Really
         Has. Quality Improvements & Price Reductions Can be
               Q     y p
         Replicated.

     • A Company Should Proactively Make its Own Products Obsolete
       Before Competitors Do.

            –    Creative Destruction
            –    Planned Obsolescence




13 | 12/3/2012
•OHLCCursor
•Chart Scale
•CHART SETTINGS
       Values


                                   NFLX
•RESET




                                          Netflix




                                    Blockbuster




                  14 | 12/3/2012
Impact on Investment Value

     •        Innovation is Important to Financial Markets in Determining the
              Value of a Company over the Long Term

     •        About 91% of Executives Surveyed Consider Increasing the
              Company's Capacity for Innovation was Critical to Creating Future
              Competitive Advantage and Earning Profits1

     •        Fortune Magazine: “Secrets of America’s Most Admired
              Corporations”- New Ideas and New Products are the Key2
                 p                                                 y




1   A study by Bain & Co. published in Harvard Business Review (Oct 2002)
                      Co                                       (Oct.
2   B. O’Reilly, “Secrets of America’s Most Admired Corporations: New Ideas, New Products.” Fortune


         15 | 12/3/2012
America’s Most Admired Companies
                 Rank                         Company
                     1                          Apple
                     2                         Google
                     3                       Amazon.com
                     4                        Coca Cola
                                              Coca-Cola
                     5                           IBM
                     6                         FedEx
                     7                   Berkshire Hathaway
                     8                        Starbucks
                     9                    Procter & Gamble
                    10                    Southwest Airlines
                      Most Admired Linked to Most Innovative!

 Source: Fortune, March 2012

16 | 12/3/2012
Top 10 Most Innovative Companies
          Rank 2012           Rank 2011             Company
                 1                1                   Apple
                 2                2                  Google
                 3                3                    3M
                 4                7                 Samsung
                 5                4              General Electric
                 6                5                 Microsoft
                 7                9                  Toyota
                 8                8             Procter & Gamble
                 9                6                    IBM
                 10              n/a                 Amazon
                      Most Admired Linked to Most Innovative!

 Source: Booz & Company Inc

17 | 12/3/2012
How Difficult is Product Innovation?

       •          Expected Failure Rate is 35% - 45% and Depends on the Industry1
       •          An Estimated 46% of all Resources Allocated to Product
                  Development are Spent on Cancelled or Failed Products1
       •          56% of Products Meet Their Market Objective and About 50%
                  Launch on Time2
       •          The Consumer Electronics Show (CES) is the Biggest Stage of the
                  Technology Industry
              –         Most of the Products Showcased This Year Will Not See
                        Commercialization!!

    Boosting a Steady Stream of Successful New Products is Not an Easy Task.

1   Robert G. Cooper: Product Leadership 2nd edition.
2   Behnam Tabrizi and Rick Walleigh “Defining Next-Generation Products” Harvard Business Review.


       18 | 12/3/2012
How Difficult is Product Innovation?

    10,000
                                                                                      “If we knew what we were doing,
                                   3000 Raw Ideas (Unwritten)
                                                                                      it wouldn’t be called research
                                                                                         wouldn t           research,
                  1000                                                                would it?” — Albert Einstein
Number of Ideas




                                         300 Ideas Submitted
          I




                    100                            125 Small Projects

                                                         9 Early Stage Development
                      10
                       0
                                                                   4 Major Development
                                                                        1.5 Launches
                        1                                                                1 Success
                               1    2     3    4    5    6   7
                               Stage of New Product Development Process

                    Source: G. Stevens and J. Burley, “3000 Raw Ideas = 1 Commercial Success!”
                    Research•Technology Management, 40(3): 16-27, May-June, 1997.

                  19 | 12/3/2012
Agenda


                 Importance of Achieving Success in Innovation
                 & Product Leadership

                 A Roadmap for Success




20 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                                     Metrics
                                                                                                                                                    Balanced
                                                                                                                                                    Scorecard
                                                                            Customers, Market Environment & Senior Mgt Team
                                           ology Strategy

                                                                                                                                                            Performance
                                                                                                                                                               Goals
                                                                                                                                      ENABLERS
 orporate Strategy




                                                                                                                                           DFSS &
                                                                                                                                    Lean PD TOOLS
                                                                   ment
                                                              Portfolio
                         Innovation & Techno




                                                                                                                                                     Outputs
                                                            Managem




                                                                                                                          Stage 5
                                                                                                                Stage 4
                                                                                     Stage 2
                                                                          Stage 1

                                                                                                                                    ORGANIZATION




                                                                                                      Stage 3
                                                                                                                                       & PEOPLE
                                                                                                                                                                ∑
Co




                                                                                                                                     TECHNOLOGY


                                                                                                                                             Gaps Between Actual
                                                                                                                                               & Desired Goals
                                                                          Lean/Sigma Design Product Development Process

                                                                                                                                               Desired Goals
                                                                                               Best Practice Sharing




                      21 | 12/3/2012
Success Through Innovation is Key

    • About 50% of Executives Consider Innovation Very Critical1

    • More than 54% Indicated Increased Investment in the Last Two
         Years1

    • Ab t 90% of Executives Consider O
      About     fE     ti    C   id Organic G
                                         i Growth Th
                                               th Through
                                                        h
         Innovation Essential to Success2

    • About 70% of Senior Executives Say That Innovation in One of the
         Top Three Drivers of Growth for Their Company in the Next 3-5
         Years3

                                                   Innovate or Die!

1   Cheskin and Fitch: Worldwide, 2003
2   The Boston Consulting Group, innovation 2005
3   The McKinsey Quarterly September 2007

       22 | 12/3/2012
The Building Blocks For Innovative Organizations1

         • Formally Integrate Innovation Into the Strategic Management
               Agenda of Senior Leaders
         • Create the Conditions That Allow Dynamic Innovation Networks to
               Emerge and Flourish
         • T k Explicit St
           Take E li it Steps to Foster an Innovation Culture Based on Trust
                              t F t        I     ti C lt      B   d    T t
               Among Employees
                       –     People Understand That Their Ideas are Valued
                                p
                       –     Trust That its Safe to Express Those Ideas
                       –     Create High Risk – High Reward Environment
                       –     Publicize Important Failures

                        Innovation is an Important Driver for Growth
1   Leadership & Innovation, The McKinsey Quarterly Jan. 2009


      23 | 12/3/2012
Fail-
Publicize Important Failures (Internally)                                                                       Forward
                                                                                                                Culture


                                                                                     Don’t Punish
                                                                                     D ’t P i h
     Discuss Failure                          Publish Failures
                                                                                   Appropriate Failure


  To promote appropriate risk taking,         3M reinforces its culture of risk          Approximately 90 grants of $50K
  Former Lockheed Martin CEO,                 taking by sharing stories of               are given to 3M employees each
  Dan Haughton, gathered the                  past failures and second                   year to pioneer new product
  company’s manufacturing                     chances.                                   ventures. The product champion
                                                                                                       p           p
  executives to discuss his own                                                          recruits his / her own team to develop
  failures, including the admission           One example is Francis Okie’s              and launch the product.
  that the failure to purchase the            1922 attempt to replace razor
  Douglas Aircraft company was a              blades with a new sandpaper                If the venture does not succeed team
                                              product. The product failed as a
  costly mistake.
                                              shaving tool but was ultimately the
                                                       tool,
                                                                                         members are guaranteed their
                                                                                                      g
                                              basis for a successful line of fine-       previous jobs. There is no
                                              grained, waterproof sandpaper              punishment for a product failing in the
                                              products.                                  market.

                                                                                                            Post-It
                                                                                                            Post It notes were
                                                                                                            developed by
                                                                                                            accident. Intolerance
                                                                                                            for failure likely
                                                                                                            would have killed the
                                                                                                            concept.p

Source: Corporate Executive Board, Tuck Business School Center for Global Leadership, 3M Company Website

     24 | 12/3/2012
Covidien’s Strategic Initiatives

 •     Innovation
 •     Portfolio Management
 •     Operational Excellence
 •     Globalization
 •     Talent management




           Innovation is a Key Component of Covidien’s Strategy




25 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                               Metrics
                                                                                                                                              Balanced
                                                                                                                                              Scorecard
                                                                          Customers, Market Environment & Senior Mgt Team
                                         ology Strategy

                                                                                                                                                      Performance
                                                                                                                                                         Goals
                                                                                                                                ENABLERS
 orporate Strategy




                                                                                                                                     DFSS &
                                                                                                                              Lean PD TOOLS
                                                                 ment
                                                            Portfolio
                       Innovation & Techno




                                                                                                                                               Outputs
                                                          Managem




                                                                                                                    Stage 5
                                                                                                          Stage 4
                                                                                   Stage 2
                                                                        Stage 1


                                                                                                                              ORGANIZATION




                                                                                                Stage 3
                                                                                                                                 & PEOPLE
                                                                                                                                                          ∑
Co




                                                                                                                               TECHNOLOGY


                                                                                                                                       Gaps Between Actual
                                                                                                                                         & Desired Goals
                                                                        Lean/Sigma Design Product Development Process

                                                                                                                                         Desired Goals
                                                                                         Best Practice Sharing




                      26 | 12/3/2012
New Product Innovation Strategy

 •          Without a Sound Strategy, a New Product is Most Likely to Fail

       –           Successful Companies Implement a Company-Specific Approach Driven by
                                    p      p                p y p          pp              y
                   Business Objectives and Strategies with a Well-Defined Product Innovation
                   Strategy at its Core1


 •          Innovation Strategy is a Component of the Overall Business
            Strategy2

       –           Includes Defined Goals that Tie to the Overall Company Strategy
       –           Includes Deployment Decisions
       –           Includes Attack and Entry Points to Markets
       –           Forms the Basis for Project Selection and Portfolio Management
                                          j                                g
       –           Well Communicated



1 Booz-Allen&   Hamilton, New product management
2 Product   Leadership, Robert Cooper 2nd ed. 2002

  27 | 12/3/2012
Key Questions to Ask for a Robust Innovation
    Strategic Plan1
    •         What Markets Do We/Can We Serve?
    •         In What Segments Do We & Our Competitors Actively Participate?
    •         How Large is the Business Opportunity?
    •         What are the Key Value Propositions?
    •         What Will We Establish as the Major Differentiators?
    •         What are the Platforms to Address the Targeted Customer and
              Markets?
    •         What are the Resources Required to Deliver Against the Product
              and Technology Strategic Plans?
    •         What is the Expected Business Outcome?
    •         How Will this Strategy Integrate with the Corporate Strategy?

1   Maurice F. Holmes and R.B. Campbell Jr.


     28 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                               Metrics
                                                                                                                                              Balanced
                                                                                                                                              Scorecard
                                                                          Customers, Market Environment & Senior Mgt Team
                                         ology Strategy

                                                                                                                                                      Performance
                                                                                                                                                         Goals
                                                                                                                                ENABLERS
 orporate Strategy




                                                                                                                                     DFSS &
                                                                                                                              Lean PD TOOLS
                                                                 ment
                                                            Portfolio
                       Innovation & Techno




                                                                                                                                               Outputs
                                                          Managem




                                                                                                                    Stage 5
                                                                                                          Stage 4
                                                                                   Stage 2
                                                                        Stage 1


                                                                                                                              ORGANIZATION




                                                                                                Stage 3
                                                                                                                                 & PEOPLE
                                                                                                                                                          ∑
Co




                                                                                                                               TECHNOLOGY


                                                                                                                                       Gaps Between Actual
                                                                                                                                         & Desired Goals
                                                                        Lean/Sigma Design Product Development Process

                                                                                                                                         Desired Goals
                                                                                         Best Practice Sharing




                      29 | 12/3/2012
Portfolio Management

•         Portfolio Management– Focuses on:
               −     New Opportunities, New Products, New Ventures
               −     All Products a Company has in Development or Available for
                     Customer at any Time
•         The Goals are:
               −     Maximize Value
                     *   Net Present Value (NPV)
                     *   Expected Commercial Value (ECV)
                     *   Internal Rate of Return (IRR)
               −     Balanced Portfolio (Short vs. Long Term, Breakthrough vs. Line
                     Extension, etc.)
               −     Strategic Alignment



    30 | 12/3/2012
Portfolio Management Practices
                                                                                                      Worst Performers
                                                          4
  Formal Portf. Mgnt. Process in Place                                                 31             Best Performers

                                                                                                      46
             Alignment with Bus. Strategy                                                                               66

                                                          4
    Good Balance Projects/Resources                                                         38

                                                                   12
                    Good Project Prioritization                                                  41
                                                               8
Resource Breakdown Reflects Strategy                                                                                     66

                                                                             19        31
            Excellent Balance of Projects

                                                      1
                                                                                            38
 Portfolio Contains High Value Projects
 P tf li C t i Hi h V l P j t


                                                  0           10        20        30        40        50      60        70

 Source: Product Development Institute 2010.                                 %
   31 | 12/3/2012
Is This a Balanced Portfolio?
                                                                                   High

   Potential Stars




                                                                            cess
   (Pearls)




                                                                  hnical Succ
                                                                                                      Bread & Butter




                                                  Probabili of Tech
   $14 M               12        10        8                                              6   4   2         0


                                                                                                       Reward (NPV)

                                                          ity



                                                                                                  White Elephants
          Long Shots                                                               Low
          (Oysters)
                                       Risk Reward Bubble Diagram
Source: Robert G. Cooper: Winning at
                                          Circle Size = Resources (annual)
New Products, 3rd edition.

      32 | 12/3/2012
Balance of Products in the Portfolio – Product
   Life Cycle
                                            (3) Cash from
                                            (2)Cash from ‘C’‘B’
                                            used to support ‘D’
                                            supports growth of D
Sales                                       (1) through used to
                                            ‘C’ ‘A’ is at maturity
                                            The possibly growth
                                            and product
                                            stage – extension
                                            finance cash cow.
                                            stage and to
                                            portfolio – four
                    ( )
                    (1)   ( )
                          (2)   ( )
                                (3)         Generates .
                                            launch ‘D’. the for
                                            strategy Din funds
                                            products
                                            the development of
                                            portfolio
                                            ‘A’ now possiblyaa
                                            ‘D’
                                            “B” Now possibly
                                            dog?
                                            Dog?


                                                     D

                                      B
                                A                C


                                          Time

   33 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                               Metrics
                                                                                                                                              Balanced
                                                                                                                                              Scorecard
                                                                          Customers, Market Environment & Senior Mgt Team
                                         ology Strategy

                                                                                                                                                      Performance
                                                                                                                                                         Goals
                                                                                                                                ENABLERS
 orporate Strategy




                                                                                                                                     DFSS &
                                                                                                                              Lean PD TOOLS
                                                                 ment
                                                            Portfolio
                       Innovation & Techno




                                                                                                                                               Outputs
                                                          Managem




                                                                                                                    Stage 5
                                                                                                          Stage 4
                                                                                   Stage 2
                                                                        Stage 1


                                                                                                                              ORGANIZATION




                                                                                                Stage 3
                                                                                                                                 & PEOPLE
                                                                                                                                                          ∑
Co




                                                                                                                               TECHNOLOGY


                                                                                                                                       Gaps Between Actual
                                                                                                                                         & Desired Goals
                                                                        Lean/Sigma Design Product Development Process

                                                                                                                                         Desired Goals
                                                                                         Best Practice Sharing




                      34 | 12/3/2012
Product Development Stage Process

•          An Operational Map For Moving New Product Projects From Idea
           to Launch

•          It is Like a Playbook in a Football Game
                − It Maps Out What Needs to be Done, Play by Play Huddle by
                                               Done          Play,
                     Huddle and How to Do it in Order to Win The Game

•          Each Stage Has Clearly Defined Deliverables
                   g            y

•          Each Stage is Cross Functional
                − No Department Owns Any One Stage




    35 | 12/3/2012
Typical Stage Gate Process

            The Five Stages of Product Development




                                                                             Ve
                                    Feasibility of Concept
                                    F




                                                                              erification & Valida



                                                                                                          Commer
                 Idea Ge




                                                              Devel



                                                                                        n
                                              y




                                                                                                               rcializatio
                                                                  lopment
                       eneration
                               n




                                                                                                                         on
                 Stage
                    g              Stage                     Stage          Stage                ation   Stage
                                                                                                            g                 Post Launch
                   1                 2                         3              4                            5                  Surveillance



Successful New Product Launches Go Through the Process


36 | 12/3/2012
Common Errors & Pitfalls in a Gated Process

•         Too Many Bad and in Trouble Projects are Sliding Through

•         The Stages Have No Teeth: Once Approved, Projects Never Get
                                         Approved
          Killed

•         Resource are Either Not Committed as Projects Move From Stage to
          Stage or Committed t T M
          St       C    itt d to Too Many P j t at a Ti
                                          Projects t Time

•         Executive Pet Projects Get Special Treatment and Bypass the Stages

•         Deliverables Overkill

•         Process is Too Rigid and Not Scalable



    Gated Process is Not a Magic Bullet: It is Only One Piece of the Puzzle
                             g                    y


    37 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                               Metrics
                                                                                                                                              Balanced
                                                                                                                                              Scorecard
                                                                          Customers, Market Environment & Senior Mgt Team
                                         ology Strategy

                                                                                                                                                      Performance
                                                                                                                                                         Goals
                                                                                                                                ENABLERS
 orporate Strategy




                                                                                                                                     DFSS &
                                                                                                                              Lean PD TOOLS
                                                                 ment
                                                            Portfolio
                       Innovation & Techno




                                                                                                                                               Outputs
                                                          Managem




                                                                                                                    Stage 5
                                                                                                          Stage 4
                                                                                   Stage 2
                                                                        Stage 1


                                                                                                                              ORGANIZATION




                                                                                                Stage 3
                                                                                                                                 & PEOPLE
                                                                                                                                                          ∑
Co




                                                                                                                               TECHNOLOGY


                                                                                                                                       Gaps Between Actual
                                                                                                                                         & Desired Goals
                                                                        Lean/Sigma Design Product Development Process

                                                                                                                                         Desired Goals
                                                                                         Best Practice Sharing




                      38 | 12/3/2012
Enablers - DFSS Tools


      • Help Define Customer Requirements (CTQ’s)

      • Result in Significant Improvement to Product Quality &
        Reliability Levels

      • C t ib t to Revenue Growth, Customer Delight, M k t
        Contributes t R      G  th C t       D li ht Market
        Share, Volume, Price

      • Warranty Cost Reductions
               y

      • Customer Satisfaction / Targets Met

      • Focus the product development teams on what is important

                  Design for Six Sigma as an Enabler


39 | 12/3/2012
DFSS Tools Used Early in The Process
   Why Important?

      Cost to Correct Quality and Reliability       Traditional Six Sigma & Lean Efforts are Focused Here




                                                $
                                                                DFSS Efforts
                                                              are Focused Here
         t




                                                                                                                Post Launch
                                                            Research         Design    Development   Launch     Performance

 Defects are:                                               Difficult to See/Predict
                                                            Easy to Fix
                                                                                                              Easy to See
                                                                                                              Costly to Fix




                                                Best $ Opportunities Realized Through Product Design

40 | 12/3/2012
Application of Lean to Product Development

Approach         Description                         Focus
Lean Product     Largely based on the adaptation     Time to market,
                                                             market
Development      of process, organization, and       development costs,
System           tools used in Toyota Product        capacity, quality,
                 Development System (TPDS) to        continuous
                 develop products better, faster,    improvement
                 and cheaper

Lean Business    Application of Lean Principles to   Time to market,
Process          minimize waste in Business          development costs,
                 Processes                           capacity

Lean Design      Elimination of waste from the       Product cost, quality,
                 product design to reduce            customer value
                 manufacturing costs



41 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                              Metrics
                                                                                                                                             Balanced
                                                                                                                                             Scorecard
                                                                         Customers, Market Environment & Senior Mgt Team
                                        ology Strategy

                                                                                                                                                     Performance
                                                                                                                                                        Goals
                                                                                                                               ENABLERS
 orporate Strategy




                                                                                                                                    DFSS &
                                                                                                                             Lean PD TOOLS
                                                                ment
                                                           Portfolio
                      Innovation & Techno




                                                                                                                                              Outputs
                                                         Managem




                                                                                                                   Stage 5
                                                                                                         Stage 4
                                                                                  Stage 2
                                                                       Stage 1


                                                                                                                             ORGANIZATION




                                                                                               Stage 3
                                                                                                                                & PEOPLE
                                                                                                                                                         ∑
Co




                                                                                                                              TECHNOLOGY


                                                                                                                                      Gaps Between Actual
                                                                                                                                        & Desired Goals
                                                                       Lean/Sigma Design Product Development Process

                                                                                                                                        Desired Goals
                                                                                        Best Practice Sharing




                     42 | 12/3/2012
…but there is clearly no standard for which
Most organizations are satisfied        innovation metrics are most effective.
with their innovation metrics…




 % of respondents who use more than 3
 innovation metrics, n=633




                                        % of respondents who use more than 3 innovation
                                        metrics, n=633

    Approximately 75% of Companies Studied Use Innovation Metrics in
    Some Form, with an Average of Eight Metrics Used
         Form                                   Used.
Source: McKinsey Quarterly


    43 | 12/3/2012
Breakdown of Projects by Project Type (%)

 45                                                  40      Best Performers
                                                                                   40
 40                                                          Worst Performers

 35
                                            28
                                                                                        27
 30                                                             25
 25
%                                                                    19
 20
                          12
 15

 10                6

    5

    0
           Packg Changes                Incremental         Major Product        New to the
                                       Improvement           Revisions         Business/World

Source: Robert G. Cooper: Product Leadership 2nd edition.


  44 | 12/3/2012
Percentage of Revenue and Profits from New Products

                                                                 42.4
  45                                                                            Revenue
                                                            38                  Profits
  40

  35
                     27.5     28.4
  30

  25
%
  20

  15                                                                        9     9.1
                                                                                  91
  10

    5

    0
                   Ave. Business                     Top 20% of         Bottom 20% of
                                                     Businesses          Businesses

Source: Robert G. Cooper: Product Leadership 2nd edition.


  45 | 12/3/2012
Success, Fail & Kill Rate of New Products

                    79.5
                                                                         Top 20% of Businesse
 80
                                                                         Bottom 20% of Businesses
 70

 60

 50                             37.6
%40
                                                                  28.4                 25.7
 30

 20
                                                            8.1
                                                                               4.3
 10

   0
                    Success                             Failure                Late Kill


Source: Robert G. Cooper: Product Leadership 2nd edition.


  46 | 12/3/2012
% On Time & On Budget for New Products

                    79.4                                    79
 80                                                                     Top 20% of Businesse

 70                                                                     Bottom 20% of Businesses

 60
                                                                                        44.3
                                                                                        44 3
 50
%
 40

 30                            20.5
                                                                                17.2
                                                                 15.5
 20

 10

   0
                   On Time                            On Budget                 Slip rate
Source: Robert G. Cooper: Product Leadership 2nd edition.


  47 | 12/3/2012
% New Product Projects Meeting Objectives

                                                                   Top 20% of Businesse
 100
                                                                   Bottom 20% of Businesses
   90                 77.1
                                                            74.5
                                                            74 5                 73.4
                                                                                 73 4
   80
   70
   60
% 50
                                                                                          29.3
   40                            26.9                              29.6
   30
   20
   10
     0
                   Meeting Profit                   Meeting Sales         Meeting Market Share
                    Objectives
                      j                              Objectives
                                                        j                      Objectives
                                                                                  j
Source: Robert G. Cooper: Product Leadership 2nd edition.


  48 | 12/3/2012
Top 10 R&D Metrics Used Across Industries
                                                                        % Companied
     Metric                                                             Using Metric
1.       R&D Spending as a % of Sales                                        77%
2.       Total Patents Filed/Pending/Awarded/Rejected                        61%
3.       Total Current R&D Headcount                                         59%
     •    Many Companies Invest Only in R&D Resources. Product Development is
4.       Cu e
         Current-Year % Sa es Due to New Products Released in Past X Years
                  ea    Sales ue o e       oduc s e eased      as     ea s 56%
          not Just R&D
             tJ t
5.       Number of New Products Released                                     53%
6. • Number Invest in Other Support Functions (QA, Manufacturing, Procurement,
      Must of Products/Projects in Active Development                     47%
7.
7
           Engineering, etc)
         % Resources/investments Dedicated to New Product Development        41%
8. • Number of Products in Defined/Planning/Estimation Stages
      A Study by Booz Allen showed no Correlation Between:                   35%
9.       − R&D to Sales Ratio, Projects Payback
    Average Project ROI or AverageR&D to Sales Growth, R&D to Gross, Net Profits
                                                                         31%
10.
10 Percentage Increase/Decrease in R&D Headcount                         31%
     • However, most Innovative Companies outperformed their peers with respect
       to revenue growth, EBITA as a percentage of revenue, and market cap
       growth

         Source: industryweek May 2008


     49 | 12/3/2012
Top 10 Innovators vs. Top 10 Spenders

                                      80
                                                          Top Innovators
 80                                             6
                                                67          p p
                                                          Top Spenders
 70                   56
                                                            54
 60
 50                           42
%40                                                                   35

 30
 20
 10
   0
              Revenue Growth       EBIT as % of      Market Cap Growth
                                    Revenue

                      5-yr CAGR      5-yr Ave             5-yr CAGR
Source: Booz Allen.


  50 | 12/3/2012
Top 10 R&D Spenders
   Rank               Rank     Company             Spend        % of
   2010               2009                         $Billion     Sales
            1             1    Roche Holdings      $9.65        21.1%
            2             5    Pfizer              $9.41        13.9%
            3             6    Novartis            $9.07        17.9%
            4             2    Microsoft
                               Mi     ft           $8.71
                                                   $8 71        14.0%
                                                                14 0%
            5             14   Merck               $8.59        18.7%
            6             4      y
                               Toyota              $8.55        3.9%
            7             10   Samsung             $7.87        5.9%
            8             3    Nokia               $7.78        13.8%
            9             11   General M t
                               G     l Motors      $6.96
                                                   $6 96        5.1%
                                                                5 1%
          10              7    J&J                 $6.84        11.1%
                It is not How Much you Spend, It is How you Spend it!
Source: Booz Allen 2011

  51 | 12/3/2012
R&D Spending - Medical Device Companies
                      16%


                            11.8%   11.6%
                      12%
                                            10.6%
                                                    9.3%
                                                    9 3%   9.2%
                                                           9 2%
   % of Total Sales




                                                                  7.8%
                      8%                                                 7.2%   6.8%
                                                                                       6.1%
                                                                                              4.8%
                      4%



                      0%




  • Data for GE, Siemens and Phillips are for their healthcare business only
  • J&J and Abbott numbers include the pharma spend



52 | June 6, 2012
Top 10 R&D Metrics Used By Industry
                                                                           %C
                                                                            Companied
                                                                                    i d
     Metric                                                                Using Metric
1.     R&D Spending as a % of Sales                                                 77%
2.     Total Patents Filed/Pending/Awarded/Rejected                                 61%
3.     Total Current R&D Headcount                                                  59%
4.     Current-Year % Sales Due to New Products Released in Past X Years            56%
5.     Number of New Products Released                                              53%
6.     Number of Products/Projects in Active Development                            47%
7.     % Resources/investments Dedicated to New Product Development
                                                              p                     41%
8.     Number of Products in Defined/Planning/Estimation Stages                     35%
9.     Average Project ROI or Average Projects Payback                              31%
10. Percentage Increase/Decrease in R&D Headcount                                   31%



        “If you are Not Keeping Score, you are Just Practicing”
                                                                             Vince Lombardi
       Source: industryweek May 2008


     53 | 12/3/2012
Key Components of Innovation / Product Leadership
                                                                                                                                               Metrics
                                                                                                                                              Balanced
                                                                                                                                              Scorecard
                                                                          Customers, Market Environment & Senior Mgt Team
                                         ology Strategy

                                                                                                                                                      Performance
                                                                                                                                                         Goals
                                                                                                                                ENABLERS
 orporate Strategy




                                                                                                                                     DFSS &
                                                                                                                              Lean PD TOOLS
                                                                 ment
                                                            Portfolio
                       Innovation & Techno




                                                                                                                                               Outputs
                                                          Managem




                                                                                                                    Stage 5
                                                                                                          Stage 4
                                                                                   Stage 2
                                                                        Stage 1


                                                                                                                              ORGANIZATION




                                                                                                Stage 3
                                                                                                                                 & PEOPLE
                                                                                                                                                          ∑
Co




                                                                                                                               TECHNOLOGY


                                                                                                                                       Gaps Between Actual
                                                                                                                                         & Desired Goals
                                                                        Lean/Sigma Design Product Development Process

                                                                                                                                         Desired Goals
                                                                                         Best Practice Sharing




                      54 | 12/3/2012
Best Practice for Best Practice Sharing

 • Establish a Process for Identifying Individual Best Practices
   Throughout all Appropriate Areas of the Organization

 • Create a Forum or Channel for Sharing Best Practices Formally.
   Link it to Strategy

 • Create a dedicated process/System with Clear Responsibilities

                                             p
 • Review Effectiveness of the Process and Improve




 55 | 12/3/2012
Must Do For Medical Device Product Development

•         Get Clinical Data Pre-Launch Rather Than Post Launch

•         Consider Global Product registration Requirements Early in the
                                    g            q              y
          Process

•         Integrate Package Design, Development and Validation into Product
          Development Process

•         Consider Sterilization Method Early in the Process

•         Reimbursement Considerations - second largest barrier to market
          entrance

•         Direct Input from Healthcare Professionals

•         Pricing Considerations early in the Process



    56 | 12/3/2012
Summary - Achieving Success in Product
    Design & Innovation - High Level
•     Process Must be Led by Senior Management - Walk the Talk
•     New P d t I
      N   Product Innovation and T h l
                         ti    d Technology St t i Linked t
                                            Strategies Li k d to
      Corporate Strategy
•     Portfolio Management – Alignment of Resources, Projects, Right
      Markets etc.
•     Multi Stage Product Development Process to Ensure:
        – DFSS & Lean PD Tool Usage
        – Regular Project Progress Reviews
        – Robust & Reliable Product Designs
•     Use a Balanced Score Card to Track Metrics and Provide a Closed
      Loop System with Periodic System Assessments
•     Share Best Practices


    57 | 12/3/2012
“The world we have created today
 as a result of our thinking thus far
 has
 h problems which cannot b
         bl       hi h        t be
 solved by thinking the way we
 thought when we created them.”

                       Albert Einstein



                   Thank you
                         y
  58 | 12/3/2012

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Product Design and Innovation - Nina Kohnen, Covidien

  • 1. Product Design & Innovation Medical Devices Summit – Colorado Springs 2012 Nina Kohnen Director Operational Excellence, Design Excellence
  • 2. Agenda Importance of Achieving Success in Innovation & Product Leadership A Roadmap for Success 2 | 12/3/2012
  • 3. About Covidien • Global manufacturer of medical devices and pharmaceuticals • 43,000 employees with 51 manufacturing facilities located i 18 countries f iliti l t d in ti • 2012 Sales – $11.9 Billion Medical Supplies Nursing Care, SharpSafety, Medical Surgical, OEM Surgical 15% 17% 68% Medical Devices Endomechanical, Energy, Pharmaceuticals Soft Tissue Repair, Specialty Pharmaceuticals, Airway & Ventilation, Contrast Products, Oximetry & Monitoring, Radiopharmaceuticals, p Vascular Active Pharmaceutical Ingredients 3 | 12/3/2012
  • 4. Achieving Market Leadership “Best Product” Innovation / Product Leadership Apple, Google, Intel, Nike, 3M Wal-Mart, FedEx, Southwest, Dell Airborne Express, Home Depot, IBM Operational Excellence Customer Intimacy Best Total Cost, Ease of Use “Best Total Solution” Convenience, Convenience etc Source: The Discipline of Market Leaders- Michael Treacy 4 | 12/3/2012
  • 5. There is no Shortage of Advice on How to do it Right Bring clarity and certainty through analysis Reduce complexity by focusing on process design Take larger strides to a e a ge st des speed up the pace of improvement Fix execution to accelerate improvement 5 | 12/3/2012
  • 6. What is Innovation? 6 | 12/3/2012
  • 7.
  • 8. This is one of very few 7 stars hotel in the world It was built in only 18 months... And opened its doors in 2003..... 8 | 12/3/2012
  • 9. 9 | 12/3/2012
  • 11. What About These Innovations? • Apple vs. Rest • DVD vs. Streaming Video • Mobile Phones vs. Landlines • E-mail vs. Snail Mail • Paper Maps vs. GPS 11 | 12/3/2012
  • 12. My Take on Innovation • Innovation is the Ability to Invent, Commercialize and Expand a Product or Service Along a Customer’s Dimension of Value. Customer s – Invention Requires a System to Generate, Prioritize & Process Ideas – Commercialization Requires a Robust Product Development Process to Launch Ideas – Expansion Requires a System to Fully Manage & Exploit Post Launch Utilization of the New Products or Services 12 | 12/3/2012
  • 13. Why is Innovation Important? • Innovation is the Only Competitive Advantage a Company Really Has. Quality Improvements & Price Reductions Can be Q y p Replicated. • A Company Should Proactively Make its Own Products Obsolete Before Competitors Do. – Creative Destruction – Planned Obsolescence 13 | 12/3/2012
  • 14. •OHLCCursor •Chart Scale •CHART SETTINGS Values NFLX •RESET Netflix Blockbuster 14 | 12/3/2012
  • 15. Impact on Investment Value • Innovation is Important to Financial Markets in Determining the Value of a Company over the Long Term • About 91% of Executives Surveyed Consider Increasing the Company's Capacity for Innovation was Critical to Creating Future Competitive Advantage and Earning Profits1 • Fortune Magazine: “Secrets of America’s Most Admired Corporations”- New Ideas and New Products are the Key2 p y 1 A study by Bain & Co. published in Harvard Business Review (Oct 2002) Co (Oct. 2 B. O’Reilly, “Secrets of America’s Most Admired Corporations: New Ideas, New Products.” Fortune 15 | 12/3/2012
  • 16. America’s Most Admired Companies Rank Company 1 Apple 2 Google 3 Amazon.com 4 Coca Cola Coca-Cola 5 IBM 6 FedEx 7 Berkshire Hathaway 8 Starbucks 9 Procter & Gamble 10 Southwest Airlines Most Admired Linked to Most Innovative! Source: Fortune, March 2012 16 | 12/3/2012
  • 17. Top 10 Most Innovative Companies Rank 2012 Rank 2011 Company 1 1 Apple 2 2 Google 3 3 3M 4 7 Samsung 5 4 General Electric 6 5 Microsoft 7 9 Toyota 8 8 Procter & Gamble 9 6 IBM 10 n/a Amazon Most Admired Linked to Most Innovative! Source: Booz & Company Inc 17 | 12/3/2012
  • 18. How Difficult is Product Innovation? • Expected Failure Rate is 35% - 45% and Depends on the Industry1 • An Estimated 46% of all Resources Allocated to Product Development are Spent on Cancelled or Failed Products1 • 56% of Products Meet Their Market Objective and About 50% Launch on Time2 • The Consumer Electronics Show (CES) is the Biggest Stage of the Technology Industry – Most of the Products Showcased This Year Will Not See Commercialization!! Boosting a Steady Stream of Successful New Products is Not an Easy Task. 1 Robert G. Cooper: Product Leadership 2nd edition. 2 Behnam Tabrizi and Rick Walleigh “Defining Next-Generation Products” Harvard Business Review. 18 | 12/3/2012
  • 19. How Difficult is Product Innovation? 10,000 “If we knew what we were doing, 3000 Raw Ideas (Unwritten) it wouldn’t be called research wouldn t research, 1000 would it?” — Albert Einstein Number of Ideas 300 Ideas Submitted I 100 125 Small Projects 9 Early Stage Development 10 0 4 Major Development 1.5 Launches 1 1 Success 1 2 3 4 5 6 7 Stage of New Product Development Process Source: G. Stevens and J. Burley, “3000 Raw Ideas = 1 Commercial Success!” Research•Technology Management, 40(3): 16-27, May-June, 1997. 19 | 12/3/2012
  • 20. Agenda Importance of Achieving Success in Innovation & Product Leadership A Roadmap for Success 20 | 12/3/2012
  • 21. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 21 | 12/3/2012
  • 22. Success Through Innovation is Key • About 50% of Executives Consider Innovation Very Critical1 • More than 54% Indicated Increased Investment in the Last Two Years1 • Ab t 90% of Executives Consider O About fE ti C id Organic G i Growth Th th Through h Innovation Essential to Success2 • About 70% of Senior Executives Say That Innovation in One of the Top Three Drivers of Growth for Their Company in the Next 3-5 Years3 Innovate or Die! 1 Cheskin and Fitch: Worldwide, 2003 2 The Boston Consulting Group, innovation 2005 3 The McKinsey Quarterly September 2007 22 | 12/3/2012
  • 23. The Building Blocks For Innovative Organizations1 • Formally Integrate Innovation Into the Strategic Management Agenda of Senior Leaders • Create the Conditions That Allow Dynamic Innovation Networks to Emerge and Flourish • T k Explicit St Take E li it Steps to Foster an Innovation Culture Based on Trust t F t I ti C lt B d T t Among Employees – People Understand That Their Ideas are Valued p – Trust That its Safe to Express Those Ideas – Create High Risk – High Reward Environment – Publicize Important Failures Innovation is an Important Driver for Growth 1 Leadership & Innovation, The McKinsey Quarterly Jan. 2009 23 | 12/3/2012
  • 24. Fail- Publicize Important Failures (Internally) Forward Culture Don’t Punish D ’t P i h Discuss Failure Publish Failures Appropriate Failure To promote appropriate risk taking, 3M reinforces its culture of risk Approximately 90 grants of $50K Former Lockheed Martin CEO, taking by sharing stories of are given to 3M employees each Dan Haughton, gathered the past failures and second year to pioneer new product company’s manufacturing chances. ventures. The product champion p p executives to discuss his own recruits his / her own team to develop failures, including the admission One example is Francis Okie’s and launch the product. that the failure to purchase the 1922 attempt to replace razor Douglas Aircraft company was a blades with a new sandpaper If the venture does not succeed team product. The product failed as a costly mistake. shaving tool but was ultimately the tool, members are guaranteed their g basis for a successful line of fine- previous jobs. There is no grained, waterproof sandpaper punishment for a product failing in the products. market. Post-It Post It notes were developed by accident. Intolerance for failure likely would have killed the concept.p Source: Corporate Executive Board, Tuck Business School Center for Global Leadership, 3M Company Website 24 | 12/3/2012
  • 25. Covidien’s Strategic Initiatives • Innovation • Portfolio Management • Operational Excellence • Globalization • Talent management Innovation is a Key Component of Covidien’s Strategy 25 | 12/3/2012
  • 26. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 26 | 12/3/2012
  • 27. New Product Innovation Strategy • Without a Sound Strategy, a New Product is Most Likely to Fail – Successful Companies Implement a Company-Specific Approach Driven by p p p y p pp y Business Objectives and Strategies with a Well-Defined Product Innovation Strategy at its Core1 • Innovation Strategy is a Component of the Overall Business Strategy2 – Includes Defined Goals that Tie to the Overall Company Strategy – Includes Deployment Decisions – Includes Attack and Entry Points to Markets – Forms the Basis for Project Selection and Portfolio Management j g – Well Communicated 1 Booz-Allen& Hamilton, New product management 2 Product Leadership, Robert Cooper 2nd ed. 2002 27 | 12/3/2012
  • 28. Key Questions to Ask for a Robust Innovation Strategic Plan1 • What Markets Do We/Can We Serve? • In What Segments Do We & Our Competitors Actively Participate? • How Large is the Business Opportunity? • What are the Key Value Propositions? • What Will We Establish as the Major Differentiators? • What are the Platforms to Address the Targeted Customer and Markets? • What are the Resources Required to Deliver Against the Product and Technology Strategic Plans? • What is the Expected Business Outcome? • How Will this Strategy Integrate with the Corporate Strategy? 1 Maurice F. Holmes and R.B. Campbell Jr. 28 | 12/3/2012
  • 29. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 29 | 12/3/2012
  • 30. Portfolio Management • Portfolio Management– Focuses on: − New Opportunities, New Products, New Ventures − All Products a Company has in Development or Available for Customer at any Time • The Goals are: − Maximize Value * Net Present Value (NPV) * Expected Commercial Value (ECV) * Internal Rate of Return (IRR) − Balanced Portfolio (Short vs. Long Term, Breakthrough vs. Line Extension, etc.) − Strategic Alignment 30 | 12/3/2012
  • 31. Portfolio Management Practices Worst Performers 4 Formal Portf. Mgnt. Process in Place 31 Best Performers 46 Alignment with Bus. Strategy 66 4 Good Balance Projects/Resources 38 12 Good Project Prioritization 41 8 Resource Breakdown Reflects Strategy 66 19 31 Excellent Balance of Projects 1 38 Portfolio Contains High Value Projects P tf li C t i Hi h V l P j t 0 10 20 30 40 50 60 70 Source: Product Development Institute 2010. % 31 | 12/3/2012
  • 32. Is This a Balanced Portfolio? High Potential Stars cess (Pearls) hnical Succ Bread & Butter Probabili of Tech $14 M 12 10 8 6 4 2 0 Reward (NPV) ity White Elephants Long Shots Low (Oysters) Risk Reward Bubble Diagram Source: Robert G. Cooper: Winning at Circle Size = Resources (annual) New Products, 3rd edition. 32 | 12/3/2012
  • 33. Balance of Products in the Portfolio – Product Life Cycle (3) Cash from (2)Cash from ‘C’‘B’ used to support ‘D’ supports growth of D Sales (1) through used to ‘C’ ‘A’ is at maturity The possibly growth and product stage – extension finance cash cow. stage and to portfolio – four ( ) (1) ( ) (2) ( ) (3) Generates . launch ‘D’. the for strategy Din funds products the development of portfolio ‘A’ now possiblyaa ‘D’ “B” Now possibly dog? Dog? D B A C Time 33 | 12/3/2012
  • 34. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 34 | 12/3/2012
  • 35. Product Development Stage Process • An Operational Map For Moving New Product Projects From Idea to Launch • It is Like a Playbook in a Football Game − It Maps Out What Needs to be Done, Play by Play Huddle by Done Play, Huddle and How to Do it in Order to Win The Game • Each Stage Has Clearly Defined Deliverables g y • Each Stage is Cross Functional − No Department Owns Any One Stage 35 | 12/3/2012
  • 36. Typical Stage Gate Process The Five Stages of Product Development Ve Feasibility of Concept F erification & Valida Commer Idea Ge Devel n y rcializatio lopment eneration n on Stage g Stage Stage Stage ation Stage g Post Launch 1 2 3 4 5 Surveillance Successful New Product Launches Go Through the Process 36 | 12/3/2012
  • 37. Common Errors & Pitfalls in a Gated Process • Too Many Bad and in Trouble Projects are Sliding Through • The Stages Have No Teeth: Once Approved, Projects Never Get Approved Killed • Resource are Either Not Committed as Projects Move From Stage to Stage or Committed t T M St C itt d to Too Many P j t at a Ti Projects t Time • Executive Pet Projects Get Special Treatment and Bypass the Stages • Deliverables Overkill • Process is Too Rigid and Not Scalable Gated Process is Not a Magic Bullet: It is Only One Piece of the Puzzle g y 37 | 12/3/2012
  • 38. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 38 | 12/3/2012
  • 39. Enablers - DFSS Tools • Help Define Customer Requirements (CTQ’s) • Result in Significant Improvement to Product Quality & Reliability Levels • C t ib t to Revenue Growth, Customer Delight, M k t Contributes t R G th C t D li ht Market Share, Volume, Price • Warranty Cost Reductions y • Customer Satisfaction / Targets Met • Focus the product development teams on what is important Design for Six Sigma as an Enabler 39 | 12/3/2012
  • 40. DFSS Tools Used Early in The Process Why Important? Cost to Correct Quality and Reliability Traditional Six Sigma & Lean Efforts are Focused Here $ DFSS Efforts are Focused Here t Post Launch Research Design Development Launch Performance Defects are: Difficult to See/Predict Easy to Fix Easy to See Costly to Fix Best $ Opportunities Realized Through Product Design 40 | 12/3/2012
  • 41. Application of Lean to Product Development Approach Description Focus Lean Product Largely based on the adaptation Time to market, market Development of process, organization, and development costs, System tools used in Toyota Product capacity, quality, Development System (TPDS) to continuous develop products better, faster, improvement and cheaper Lean Business Application of Lean Principles to Time to market, Process minimize waste in Business development costs, Processes capacity Lean Design Elimination of waste from the Product cost, quality, product design to reduce customer value manufacturing costs 41 | 12/3/2012
  • 42. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 42 | 12/3/2012
  • 43. …but there is clearly no standard for which Most organizations are satisfied innovation metrics are most effective. with their innovation metrics… % of respondents who use more than 3 innovation metrics, n=633 % of respondents who use more than 3 innovation metrics, n=633 Approximately 75% of Companies Studied Use Innovation Metrics in Some Form, with an Average of Eight Metrics Used Form Used. Source: McKinsey Quarterly 43 | 12/3/2012
  • 44. Breakdown of Projects by Project Type (%) 45 40 Best Performers 40 40 Worst Performers 35 28 27 30 25 25 % 19 20 12 15 10 6 5 0 Packg Changes Incremental Major Product New to the Improvement Revisions Business/World Source: Robert G. Cooper: Product Leadership 2nd edition. 44 | 12/3/2012
  • 45. Percentage of Revenue and Profits from New Products 42.4 45 Revenue 38 Profits 40 35 27.5 28.4 30 25 % 20 15 9 9.1 91 10 5 0 Ave. Business Top 20% of Bottom 20% of Businesses Businesses Source: Robert G. Cooper: Product Leadership 2nd edition. 45 | 12/3/2012
  • 46. Success, Fail & Kill Rate of New Products 79.5 Top 20% of Businesse 80 Bottom 20% of Businesses 70 60 50 37.6 %40 28.4 25.7 30 20 8.1 4.3 10 0 Success Failure Late Kill Source: Robert G. Cooper: Product Leadership 2nd edition. 46 | 12/3/2012
  • 47. % On Time & On Budget for New Products 79.4 79 80 Top 20% of Businesse 70 Bottom 20% of Businesses 60 44.3 44 3 50 % 40 30 20.5 17.2 15.5 20 10 0 On Time On Budget Slip rate Source: Robert G. Cooper: Product Leadership 2nd edition. 47 | 12/3/2012
  • 48. % New Product Projects Meeting Objectives Top 20% of Businesse 100 Bottom 20% of Businesses 90 77.1 74.5 74 5 73.4 73 4 80 70 60 % 50 29.3 40 26.9 29.6 30 20 10 0 Meeting Profit Meeting Sales Meeting Market Share Objectives j Objectives j Objectives j Source: Robert G. Cooper: Product Leadership 2nd edition. 48 | 12/3/2012
  • 49. Top 10 R&D Metrics Used Across Industries % Companied Metric Using Metric 1. R&D Spending as a % of Sales 77% 2. Total Patents Filed/Pending/Awarded/Rejected 61% 3. Total Current R&D Headcount 59% • Many Companies Invest Only in R&D Resources. Product Development is 4. Cu e Current-Year % Sa es Due to New Products Released in Past X Years ea Sales ue o e oduc s e eased as ea s 56% not Just R&D tJ t 5. Number of New Products Released 53% 6. • Number Invest in Other Support Functions (QA, Manufacturing, Procurement, Must of Products/Projects in Active Development 47% 7. 7 Engineering, etc) % Resources/investments Dedicated to New Product Development 41% 8. • Number of Products in Defined/Planning/Estimation Stages A Study by Booz Allen showed no Correlation Between: 35% 9. − R&D to Sales Ratio, Projects Payback Average Project ROI or AverageR&D to Sales Growth, R&D to Gross, Net Profits 31% 10. 10 Percentage Increase/Decrease in R&D Headcount 31% • However, most Innovative Companies outperformed their peers with respect to revenue growth, EBITA as a percentage of revenue, and market cap growth Source: industryweek May 2008 49 | 12/3/2012
  • 50. Top 10 Innovators vs. Top 10 Spenders 80 Top Innovators 80 6 67 p p Top Spenders 70 56 54 60 50 42 %40 35 30 20 10 0 Revenue Growth EBIT as % of Market Cap Growth Revenue 5-yr CAGR 5-yr Ave 5-yr CAGR Source: Booz Allen. 50 | 12/3/2012
  • 51. Top 10 R&D Spenders Rank Rank Company Spend % of 2010 2009 $Billion Sales 1 1 Roche Holdings $9.65 21.1% 2 5 Pfizer $9.41 13.9% 3 6 Novartis $9.07 17.9% 4 2 Microsoft Mi ft $8.71 $8 71 14.0% 14 0% 5 14 Merck $8.59 18.7% 6 4 y Toyota $8.55 3.9% 7 10 Samsung $7.87 5.9% 8 3 Nokia $7.78 13.8% 9 11 General M t G l Motors $6.96 $6 96 5.1% 5 1% 10 7 J&J $6.84 11.1% It is not How Much you Spend, It is How you Spend it! Source: Booz Allen 2011 51 | 12/3/2012
  • 52. R&D Spending - Medical Device Companies 16% 11.8% 11.6% 12% 10.6% 9.3% 9 3% 9.2% 9 2% % of Total Sales 7.8% 8% 7.2% 6.8% 6.1% 4.8% 4% 0% • Data for GE, Siemens and Phillips are for their healthcare business only • J&J and Abbott numbers include the pharma spend 52 | June 6, 2012
  • 53. Top 10 R&D Metrics Used By Industry %C Companied i d Metric Using Metric 1. R&D Spending as a % of Sales 77% 2. Total Patents Filed/Pending/Awarded/Rejected 61% 3. Total Current R&D Headcount 59% 4. Current-Year % Sales Due to New Products Released in Past X Years 56% 5. Number of New Products Released 53% 6. Number of Products/Projects in Active Development 47% 7. % Resources/investments Dedicated to New Product Development p 41% 8. Number of Products in Defined/Planning/Estimation Stages 35% 9. Average Project ROI or Average Projects Payback 31% 10. Percentage Increase/Decrease in R&D Headcount 31% “If you are Not Keeping Score, you are Just Practicing” Vince Lombardi Source: industryweek May 2008 53 | 12/3/2012
  • 54. Key Components of Innovation / Product Leadership Metrics Balanced Scorecard Customers, Market Environment & Senior Mgt Team ology Strategy Performance Goals ENABLERS orporate Strategy DFSS & Lean PD TOOLS ment Portfolio Innovation & Techno Outputs Managem Stage 5 Stage 4 Stage 2 Stage 1 ORGANIZATION Stage 3 & PEOPLE ∑ Co TECHNOLOGY Gaps Between Actual & Desired Goals Lean/Sigma Design Product Development Process Desired Goals Best Practice Sharing 54 | 12/3/2012
  • 55. Best Practice for Best Practice Sharing • Establish a Process for Identifying Individual Best Practices Throughout all Appropriate Areas of the Organization • Create a Forum or Channel for Sharing Best Practices Formally. Link it to Strategy • Create a dedicated process/System with Clear Responsibilities p • Review Effectiveness of the Process and Improve 55 | 12/3/2012
  • 56. Must Do For Medical Device Product Development • Get Clinical Data Pre-Launch Rather Than Post Launch • Consider Global Product registration Requirements Early in the g q y Process • Integrate Package Design, Development and Validation into Product Development Process • Consider Sterilization Method Early in the Process • Reimbursement Considerations - second largest barrier to market entrance • Direct Input from Healthcare Professionals • Pricing Considerations early in the Process 56 | 12/3/2012
  • 57. Summary - Achieving Success in Product Design & Innovation - High Level • Process Must be Led by Senior Management - Walk the Talk • New P d t I N Product Innovation and T h l ti d Technology St t i Linked t Strategies Li k d to Corporate Strategy • Portfolio Management – Alignment of Resources, Projects, Right Markets etc. • Multi Stage Product Development Process to Ensure: – DFSS & Lean PD Tool Usage – Regular Project Progress Reviews – Robust & Reliable Product Designs • Use a Balanced Score Card to Track Metrics and Provide a Closed Loop System with Periodic System Assessments • Share Best Practices 57 | 12/3/2012
  • 58. “The world we have created today as a result of our thinking thus far has h problems which cannot b bl hi h t be solved by thinking the way we thought when we created them.” Albert Einstein Thank you y 58 | 12/3/2012