OUR PROCESS IS UNCOMPLICATED.

We utilise AGILE methodology to deliver items of work sooner, so we can design, build, test, evaluate, and identify and solve issues earlier in the process when time/cost investment is lower.

Whistle-Design-Process-2021

Our product development process consists of four main stages:. Here’s an overview of what to expect in each stage

S01. DISCOVERY.

Product Design Specification (PDS). Shared project requirements document listing every requirement and decision made.

Discovery Session. Project kick-off, team introduction and discovery meeting to discuss all project requirements.

Research. Research into market, competitors, materials, process, or manufacturing methods relevant to solving the problems.

Feasibility Study. Feasibility studies with early conceptual work to evaluate feasibility of commercialisation and identify blockers early on to de-risk investment in further stages.

Standards and Product Safety. For more information on Standards, visit Standards Australia. Further information on Product Safety (Australia), visit Product Safety Australia.

Development Plan. Evaluation of Discovery stage, go/no-go to proceed to Design, confirmation of development plan, timing and budgets.

S02. DESIGN LOOP.

Design. Proof-of-concept, aesthetic, functional or detail design.

Build. Hand builds and in-house 3d-printing for quick turnaround testing FDM, SLA, SLS, CNC, Direct-Metal 3D printing, and low-volume casting/moulding methods for accurate production material properties.

Test. To pre-defined pass/fail criteria established during the Discovery stages.

Evaluate. Review of design, build, test results and planning for next Design Loop or exit to S03 Release.

Projects typically consist of three Design loops, as follows:

L01. Proof of Concept (POC). Validation of the concept with MVP to test.

L02. Pre-Production. To achieve functional “looks like/works like” prototype for validation.

L03. Production. Final design for progression to S03 Release.

S03. RELEASE.

Final Specification. Product Design Specification up to date with all latest information.

Quality Control Documentation Or Test Specifications. Procedures for QC at production level, including specifications, go/no-go tests, rigs and assembly line tools and jigs.

Bill Of Materials (BOM). Build list with all assembly/part/drawing versions and release history and dates of all files/types packaged for suppliers

Manufacturing Drawings. Full drawing set conveying all information a supplier needs to fabricate the part CORRECTLY, without us being there to explain it.

Colour, Material And Finish (CMF) Specification. CMF document with Pantone or RAL colour references per brand guidelines, materials and finishes, referencing industry standard Mold-Tech or Yick Sang finishes where applicable.

Packaging Specification (Individual, Bulk Carton Or Otherwise). Instruction for how is the product sent from factory to you or your distribution channel.

S04. PRODUCTION.

Supplier Visits and Liaison. Supplier management, including technical support and multi-supplier co-operation. Local or overseas (at Time + Costs).

Tool Design Reviews. Review of production tool designs for items such as flow/gate/pin position to ensure best finished part quality.

Quality Assurance Documentation Or Support. Support suppliers to produce QA plans to ensure ongoing quality management.

Off-Tool Sample Reviews (OTS). Review and reporting of off-tool sample issues or approvals (Eg. T0 (Mold verification), T1, T2 etc.).

Gold Sample Specification And Storage. Inspection, documentation, approval and preparation of Gold Sample sets.

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