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All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission.
ISBN 978-0-9732827-3-3
ISBN 978-1-60197-171-5
Contributors: Rachel Brill, Marisa Brown, Rebecca Colley, and Erin Williams
For information regarding other publications by the author, seminars, and Stage-Gate solutions
please visit www.stage-gate.com.
For information regarding other publications and research conducted by the APQC please visit
www.apqc.org.
Table of Contents
1. Introduction 7
1.1 The Quest for Best Practices in Product Innovation 7
1.2 The Key Research Questions 8
1.3 Topic Areas Studied 8
1.4 How the Benchmarking Research Was Undertaken 9
1.5 Organization of the Results 12
Appendices
A. In-Depth Case Studies
1. Air Products and Chemicals, Inc. 61
2. Ashland, Inc. 77
3. Becton, Dickinson and Company (BD) 90
4. Electro Scientific Industries, Inc. (ESI) 103
5. EXFO 114
Exhibits
1.1 The Sample—Industry Breakdown 11
1.2 Selected Characteristics of Businesses in the Sample 12
2.1 Percentage of Revenues & Profits from New Products 14
2.2 Success, Fail and Kill Rates—The Average Business 15
2.3 Success, Fail and Kill Rates—Top 25% vs. Bottom 25% 15
2.4 Time to Market (Idea to Launch Months) 16
2.5 Percent of Projects On Time, On Budget—Average Business 17
2.6 Projects On Time, On Budget—Top 25% vs. Bottom 25% 18
2.7 Percent of Projects Meeting Objectives 19
2.8 Additional Performance Metrics—The Average Business 20
2.9 How Businesses Fare in Terms of Performance Metrics 21
2.10 Key Measures Used to Define New Product Success or Failure 23
2.11 Key Indicators Used to Measure the Total New Product Program 24
2.12 Performance Metrics Results—The Best vs. Worst Performers 26
2.13 Performance Metrics—The Best vs. Worst Performers 27
2.14 Breakdown of Projects by Project Type for the Average Business 28
2.15 Breakdown of Projects by Project Type: Best 25% vs. Worst 25% of Performers 29
3.1 Whether Businesses Have a Systematic NPD Process in Place 32
3.2 Impact of Having a Systematic New Product Process in Place 34
3.3 How Business Performs on Critical Pre-Development Activities 37
3.4 Gatekeeping/Governance Approaches 38
3.5 How Effective are the Gates 40
3.6 Gate Deliverables 41
4.1 Primary Approach to Establishing Project Teams 45
4.2 NPD Project Team support—Best vs. Worst 46
4.3 Who Leads the New Product Development Teams 47
4.4 Senior Leadership Support—Best vs. Worst 49
4.5 Types of NPD Training Offered 50
5.1 How Businesses Fare on Portfolio Management 54
5.2 Impact of Portfolio Management—Best vs. Worst 54
1. Introduction
1.1 THE QUE ST F OR BE ST PR ACTI CE S I N PR OD U CT INNOV AT I ON
As organizations try to move forward through what will likely be a long and bumpy economic
recovery, two key imperatives are emerging for those of us with an eye on creating future value for
our organizations.
1. We cannot manage the past.
2. In every industry, innovation is moving forward whether or not your organization is moving
with it.
As we know, the nature of the recovery, or the “new normal”, differs depending upon your industry
and the different parts of the world in which your customers are based. Still, the above principles
apply.
So, given the need to keep innovating despite resource restraints, what are other companies doing to
keep moving ahead? And what does it mean for new product development (NPD) efforts?
In this study, we benchmarked what organizations are currently doing, what best practices are, and
provide a baseline that you can use to compare against your organization’s capabilities. A number of
key themes are benchmarked including performance measures and metrics, NPD process standards
and activities, governance (gatekeeping), and culture.
For example, a complete evaluation of the performance measures that companies are using and the
typical results achieved provide a solid baseline to compare to your organization’s performance. We
gathered numerous NPD-related performance metrics including sales, profit, speed to market, and
performance versus budget. Hence, this report provides metrics that compare company or business
unit level product innovation performance and also evaluates performance at the project level.
Similarly, a detailed examination was undertaken of NPD activities at both an organizational level
(process standards) and at the project execution level (the type of activities occurring, the quality, and
their impact). Finally, we measured some aspects of culture to learn how organizations leverage
teams and support them to improve organizational capability as well as the role of the NPD process
manager.
The key challenge, of course, is how to do all of this effectively and repeatedly. In this report, we
share how best-practice organizations support product innovation processes that deliver results. The
findings present an interesting picture of what these organizations do and how they developed and
continue to manage their processes. We hope these best practices will help your organization
improve its performance in this important endeavor of managing your new product development
efforts.
NEW PRODUCT DEVELOPMENT
page 7
Copyright © 2011 by Product Development Institute and APQC
New Product Development
P R OCE SS BE NC HMARK S AND PER F OR MANC E ME TRI CS
2. NPD process: How are businesses faring on a number of practices that have been identified
over the years as positive drivers of performance? For example: Do businesses really have a
new product development process in place? Is it working? Do the early pre-development
activities impact the ultimate success of the project?
3. Gatekeeping and governance: What practices are used? How effective are gatekeeping practices?
What is the impact on success?
4. Best vs. worst companies: What are the best- or top-performing businesses doing differently
from the rest? What are some of the details and examples of best practices? How have
companies sought to leverage the people side of innovation? And additional questions.
Performance Metrics:
1. Product innovation metrics at the business unit level
4. Differences in performance between top performing companies (top 25 percent), and the
poor performing companies (bottom 25 percent)
9. The effectiveness of Gatekeeping and Governance practices including the quality of gate
deliverables and their quality
Each of these 10 key topic areas has a number of sub-items, so that a total of 68 practices, methods,
and approaches were researched.
NPD performance metrics are always a question of interest as organizations strive to benchmark
themselves against others to determine if their performance standards are acceptable or not. In this
study the performance of businesses’ new product development efforts—their total NPD
programs—was also measured. Note that NPD performance is a multi-dimensional concept, so
multiple measures of performance are used in this study. These performance measures include:
Percentage of new products meeting sales, profit, and market share objectives (3 measures)
Success, failure, and kill rates of NPD projects (3 measures)
Proportion of NPD projects on budget and on schedule (2 measures)
Average slip rates for projects behind schedule
Percentage of the business’s sales and profits generated from new products (2 measures)
Overall profitability of the business’s total new product efforts relative to spending
Time to market
Whether the business’s total NPD program has met or exceeded its sales and profit
objectives (over the last three years)
The success and profitability of the business’s total NPD program (over the last three years)
Whether the business has been able to reduce product development cycle time—
development-to-launch time—significantly over the last three years
Other key indicators used to measure performance.
From these multiple performance metrics, top performing performance dimensions were created
which enable us to identify the Best Performers in NPD.
Qualitative: Site visits were organized with five companies previously identified as having best
practices in new product development in place. The APQC research team consisted of the subject
matter expert, a number of representatives from the sponsor companies, and APQC personnel who
conducted the meetings. These on-sites visits were based on a detailed interview guide or
questionnaire, which covers essentially the same 10 topics as listed in Section 1.3.
Air Products and Chemicals, Inc. (Performance Materials Division) is engaged in high-
end, performance-specific applications, primarily in a business-to-business model and is
comprised of six business lines: specialty additives, functional additives, personal care,
reactive intermediates, polyurethane additives, and epoxy additives. The PMD group
generated about $700 million in sales in 2009.
EXFO is a leading provider of optical testing solutions and wireless protocol analyzers and
network simulators, and portable test sets for the telecommunications industry.
Quantitative: A detailed quantitative questionnaire was also constructed, focusing on the 10 topics
in Section 1.3. A total of 68 variables or measures were used to capture the existence and proficiency
of practices, approaches, and methods in the questionnaire. Additionally, some general descriptive
questions to characterize the businesses were included.
Many questions were measured on Likert-type anchored 0-10 scales—for example, questions that
sought the degree to which certain practices or methods were employed and how well, or how
successful NPD Gatekeeping practices are. Other questions were direct, seeking a quantitative
answer, such as percentage of projects that were commercial successes or failures or percentage of
projects meeting sales targets. Finally, a number of open-ended questions that sought text responses
were included.
The quantitative sample: A total of 257 business entities responded to the detailed quantitative
questionnaire. Refinement of the data sample plus the removal of small organizations led to a useable
sample of 211 respondents. Selected sample statistics are:
Businesses are in a number of different industries, with about half in the manufacturing
sector (Exhibit 1.1)
The businesses have median sales of $1 billion and the median number of employees is
2,500 (Exhibit 1.2)
Median R&D spending data is $10 million per business or 4.0 percent of sales. The mean
values are also shown in Exhibit 1.2, but are skewed by a number of very large businesses.
Service 15.6%
Chemical 7.1%
Telecommunication 5.7%
Electronics/computers 4.3%
Software 4.3%
Other 10.4%
Spending on R&D
8.2% 4.0%
(as a percent of sales)
The next section, Chapter 2, provides NPD performance results of the businesses on the
many performance metrics measured. Here, these performance metrics are also combined to
identify the Best and Worst Performers.
Chapters 3 and 4 outline how the businesses rate or fare on the different practices and
methods in each of the first 10 topic areas outlined. Additionally, each practice is measured
against performance metrics to assess how the top and bottom performers score on each.
Chapter 5 looks at portfolio management and its impact on success.
Chapter 6 outlines the Conclusions and Recommendations.
Appendix A provides detailed case descriptions from the site visits undertaken with the five
best practice companies which are presented as individual case studies.
Appendix B provides the survey data results in chart form to provide the reader with
additional points for reference and information.
Determining how your organization is performing and how it compares to other organizations is
always an interesting question. Without clear metrics and a way to compare them, it can be very hard
to know whether you are doing well or poorly at product innovation, if your investment in R&D is
producing the desired results, and what areas of your performance might need to be improved or
strengthened. In this chapter, how the businesses fare on a number of the top performance metrics is
highlighted, along with the distribution of results—the top and bottom 25 percent of businesses.
Also, based on these performance results, a subset of best performing businesses are identified,
which then help to identify best practices in subsequent chapters.
These percentages of sales revenues and profits are defined as follows: the percentage of the business
entity’s annual sales revenues (or the business’s profits) that is derived from new products launched
within the last three years.
Overall, the average percentages are impressive for new products launched within the past three
years. But most impressive are the results of performers in the top 25 percent on these two metrics:
36 percent of sales and 30.5 percent of profits coming from new products.
But words of caution: Although these are popular metrics, be aware that they are not necessarily the
right metrics to gauge performance or the only metrics to use. Here are the comments of an astute
and experienced CTO:
“Percentage of sales is a ‘good news, bad news’ metric. One of our business units has a very
high percentage of sales from new products. But this is due to a combination of negative
factors: high and costly product obsolesce in their market; new products that did not
perform—either technically or financially—and needed to be fixed and replaced; and over-
reaction to every single customer request. The result is a lot of ‘churn’ in the product line,
which is very costly to the business. So a high percentage of sales is not always a good
thing.”
Bottom 25% of
10.0% Businesses
Top 25% of
Businesses
10.0%
% of profits coming
25.2%
from NPs
30.5%
2 . 2 S UC CE SS , F AI L A ND K IL L R ATE S
Another key metric is the NPD success rate: what proportion of projects entering development
become commercial successes? Or become commercial failures? Or are killed along the way?
The average values are shown in Exhibit 2.2, while the top 25 percent and bottom 25 percent of
businesses on this metric are shown in Exhibit 2.3:
Exhibit 2.2: Success, Fail and Kill Rates – The Average Business
Commercial
Successes
Commercial Failures
Exhibit 2.3: Success, Fail and Kill Rates – Top 25% vs. Bottom 25%
Bottom 25% of
% of projects 35.0% Businesses
commercially Top 25% of
successful 70.0%
Businesses
% of projects 35.0%
commercial failures 10.0%
The result is a respectable success rate on average of 53 percent. But note the huge difference
between the top 25 percent of businesses and the bottom 25 percent on this Success Rate metric: the
top 25 percent have double the success rate of the bottom 25 percent. And the bottom 25 percent
have more than three times the failure rate of the top 25 percent. These are not small differences—
these performance differences are of great magnitude, and raise the questions: what separates the
best from the worst; and why do the top businesses do so exceptionally well?
2.3 T I ME TO MARKET
Time to market is a very typical performance metric, given the heavy emphasis placed on speed-to-
market and cycle time reduction in product innovation. The median product development time from
Idea Generation through to Product Launch is slightly less than 18 months. However, the
breakdown, by businesses, shows that a wide range in cycle times exists (see Exhibit 2.4). Note that:
The fact that, on average, more projects are behind schedule (missing their scheduled launch date)
and that a considerable percentage (43.5 percent) are over budget raises serious concerns about
scheduling, resource management, project management, and commitments to timelines. Admittedly,
there is a small group of businesses doing much better than these average businesses: 70.0 percent on
schedule and 81.0 percent on budget. But the other extreme is the bottom 25 percent, whose
performance is 3.5 times lower than the top 25 percent. The significant difference between the top
25 percent and bottom 25 percent indicates that many firms have yet to achieve acceptable on-time
and on-budget results, although a handful of firms prove that this goal can be achieved.
Exhibit 2.6: Projects On Time, On Budget – Top 25% vs. Bottom 25%
Bottom 25% of
% of projects launched
20.0% Businesses
on schedule
70.0% Top 25% of
Businesses
But how late is late? The “slip rate” measures how late a project is as a percentage of its total
scheduled time to market. On average, when a project is late to market, it is behind schedule (the
“slip rate”) by 31.4 percent, as noted in Exhibit 2.5. That is, if a project is scheduled for 18 months
time-to-market, the typical “late project” gets there in 23.6 months, i.e. 5.6 months late.
That is the data for the average business. The worst performers (bottom 25 percent on this metric)
see their “late projects” miss the scheduled launch by 40 percent, while the best drive their slip rates
down to 19 percent.
Average Bottom
Top 25%
Business 25%
The performance metric results are a cause for concern. First, the fact that the mean values are
averaging about 50 percent for all three metrics means that a sizable proportion of projects (almost
half) are failing to meet objectives. This result should be unacceptable for most senior management
teams. Next, consider the distribution of results: the top 25 percent of businesses on these metrics
are achieving almost 2.5 times the performance of the bottom 25 percent, suggesting that many
businesses have a lot of room for improvement.
33.5%
% of projects meeting sales
52.2%
objectives
70.0%
30.0%
% of projects meeting market
48.8%
share objectives
70.1%
1. Most businesses actually do keep score and measure their overall NPD performance (mean
rating: 5.4 out of 10). A surprising 11.7 percent do not, however.
2. Businesses see their NPD efforts or programs as moderately profitable relative to how much
they spend on them (mean rating: 5.8 out of 10). Only 19.2 percent see their programs as
very profitable.
3. The ability to meet profit objectives is more weakly rated on average (mean rating: 5.2 out of
10). Only 12.9 percent of businesses were very satisfied with their ability to exceed profit
objectives.
4. Meeting sales objectives was rated weakly as well (mean rating: 5.3 out of 10) and only 13.0
percent of businesses were very satisfied with their ability to exceed sales objectives.
5. Cycle time reduction is the goal in many businesses’ product innovation efforts. And so, the
ability to reduce cycle time over the last three years is a key metric. Businesses rate poorly on
this metric (mean rating: 5.2 out of 10), with only 11.6 percent of business claiming very
good results.
0 1 2 3 4 5 6 7 8 9 10
0=Not 10=Excellent,
at all The Degree that Each to a great
Performance Metric is extent
Measured
A quick glance at Exhibit 2.8 shows that mean scores fall almost entirely down the middle of the
chart, with the average business achieving a moderate-to-weak 5 to 6 out of 10 on just about every
performance metric. These depressed scores are a definite concern. The worst performance is on the
cycle reduction metric. The strongest performance metric was the business’ profitability relative to
spending over the past three years.
Thus, one set of metrics is at the project level (Exhibit 2.10); the other is at the business or business unit
level (Exhibit 2.11). The results are self-evident.
In all cases, a time frame had been defined: new products launched over the last two, three, or five
years. Often the definition of “what is a new product” proved difficult or problematic, but in better
practice firms this term had been precisely defined to enable the use of these metrics.
But words of caution: Although these are popular metrics, be aware that they are not necessarily the
right or universal metrics to gauge NPD performance. Nor will a single metric necessarily capture all
facets of new product performance. Recall the comments of the experienced CTO (Section 2.1) who
noted that “percentage of revenue” can reward or induce the wrong kind of behavior. He was not
alone. We heard a number of knowledgeable people suggesting caution in that NPD metrics, as with
all metrics, can cause or incent the wrong kind of management actions. For example, NPD
performance measured strictly by “percentage of sales from new products” will logically lead to a
NEW PRODUCT DEVELOPMENT
page 22
Copyright © 2011 by Product Development Institute and APQC
New Product Development
P R OCE SS BE NC HMARK S AND PER F OR MANC E ME TRI CS
number of short-term, fast projects (and few longer term ones); projects that generate sales but not
necessarily profits; new products that could cannibalize existing products and create a lot of
unnecessary churn in the product line; and so on.
Exhibit 2.10: Key Measures Used to Define New Product Success or Failure
Exhibit 2.11: Key Indicators Used to Measure the Total New Product Program
Other 5.9%
Numerous performance metrics were identified and investigated in this study. Previous sections in
this chapter have reported how businesses perform on these metrics. Trying to identify which
businesses are the best versus the worst on each and every metric becomes a cumbersome task;
moreover, some of these metrics are themselves inter-correlated.
As a result, a composite variable was created using responses to three key performance metrics
focusing on profits and sales. The “top” performers for this composite had consistently strong
performance across all questions, and the “bottom” performers for this composite had consistently
weak performance in the three areas. The “middle” group had any other combination of scores. The
three key measures are:
Profitability of the NPD program over the past three years relative to spending on it,
Ability to meet or exceed profit objectives over the last three years, and
Ability to meet or exceeded its sales objectives over the last three years.
Hence, a new composite variable was created that reflects the three groups’ strength on these three
metrics. Group one was very strong on achieving profit and sales results; the second group was very
poor or fell far short of profit and/or sales objectives; and a third, middle group that comprises the
rest of the respondents.
The results are overwhelming: clearly a powerful set of Best Performers that can readily compare to a
weak set of Poor Performers have been identified. There are 16 performance metrics in total
(Exhibits 2.12 and 2.13). Here we see that on all 16 metrics, the Best Performers score significantly
higher and stronger than the Worst.
For example, the Best versus the Worst Performing businesses in Exhibit 2.12:
Have much higher new product success rates (62.0 percent vs. 44.9 percent) and lower
failure rates
Have higher proportions of projects on time (60.4 percent vs. 25.5 percent) and on budget
(66.7 percent versus 40.0 percent)
Have more projects that meet their sales objectives (74.7 percent vs. 36.7 percent) and profit
objectives (about 71.8 percent vs. 36.7 percent)
See a much higher proportion of their business’s sales revenues and profits coming from
new products (about 45 percent vs. 14 percent).
Exhibit 2.12: Performance Metrics Results – The Best vs. Worst Performers
44.9% 52.2%
% of developments successful (success rate)
62.0%
34.2%
% of developments that fail (failure rate %) 27.7%
13.8%
20.9%
% of projects killed (prior to launch) 20.1%
24.3%
40.0%
% of projects on budget 61.4%
66.7%
25.5%
% of projects on schedule 46.9%
60.4%
36.7%
% of projects that met profit objectives 50.1%
71.8%
36.7%
% of projects that met sales objectives 50.1%
74.7%
43.2%
% of projects that met mkt share targets 46.7%
66.1%
16.9% 28.2%
% of revenue coming from NPs Worst Performers
46.6%
Middle Business
10.5%
% of profits coming from NPs 26.2% Best Performers
43.8%
Measure and track performance (mean rating on a 1-10 scale: 6.6 vs. 3.1)
Have more profitable NPD programs versus spending (mean rating on a 1-10 scale: 8.4 vs.
3.2)
Have NPD programs that meet the business’s profit objectives (mean rating a 1-10 scale: 8.1
vs. 1.9).
3.2
Product performance is measured 5.7
6.7
3.0
Product performance tracked centrally 5.7
6.5
3.2
Profitability vs. spending 6.0
8.4
1.9
Met/exceed profit objectives 5.6
8.1
2.3
Met/exceed sales objectives 5.5
8.2
2.2 Worst Performers
Reduction of cycle time 4.6 Middle Business
5.6 Best Performers
1 2 3 4 5 6 7 8 9 10
This is a fairly reasonable balance among projects in these three main categories. By contrast, new-to-
the-world products—true innovations—and minor development—such as promotional and package
changes—represent a minority of new products (6.7 percent and 13.4 percent, respectively).
Do the Best Performers adopt a different mix of project types—is there an optimal portfolio of
project types? Consider how the Middle businesses compare to the Best and Worst Performing
businesses—see Exhibit 2.15.
What is noteworthy is the shift towards much more innovative and/or riskier and bolder projects as
one migrates from Worst to Best businesses. For example:
More than half (57.1 percent) of Worst businesses’ projects are the small, incremental
ones—promotional/package changes or incremental product improvements and changes.
By contrast, only 40 percent of Best Performers’ projects are these small, incremental ones.
Best Performers take on a higher proportion of larger, more innovative projects: 38.2
percent of Best Performers’ projects are either new-to-the-business or true innovations—
new-to-the-world.
Exhibit 2.14: Breakdown of Projects by Project Type for the Average Business
Promotional
New product to Other development/package
world
change
2.6%
6.7% 13.4%
New product to
business 20.0%
Incremental product
34.8%
improvement/change
22.5%
Major product
revision
By contrast, only 18.1 percent of Worst Performers’ projects are these bolder projects.
Consider the last category on its own in Exhibit 2.15: Best Performers do almost three times
the number of true innovations (new-to-the-world products) projects than do Worst
Performers: 11.5 percent versus 4.1 percent.
As you progress from the worst to middle to best performers, there is a full 10 percent step
change in the project mix towards the more innovate types of projects reflecting an increase
in risk as you move from each of the three categories.
Conclusions: We cannot prove cause-and-effect here—that doing more venturesome projects will
lead to better performance results. But if you wish to benchmark the Best Performers in terms of
project types, Exhibit 2.15 is a good guide. And note the tendencies when comparing Worst versus
Best Performers—the heavy shift from small and incremental projects to bolder and more innovative
projects.
This section deals with the process that businesses use to drive new product projects from the Idea
Stage through to Launch. Specific topics in this section include:
1. A clearly defined idea-to-launch new product process: As noted, businesses rate very
high here, with 88.2 percent of businesses having such a NPD process, and only 11.9
percent scoring weakly (Exhibit 3.1). The Best Performers score 9.2 out of 10 here
compared to only 5.7 for the worst performers.
2. A visible, documented process: Some firms claim to have a NPD process; but on closer
inspection, it’s more of a high level and conceptual process—a few flow diagrams with
boxes and diamonds and little more. To be operational, an effective new product process
should be well mapped-out, visible and well-documented. Again, the sample of businesses
does fairly well, with best performers having a mean rating of 8.4 out of 10. 84.6 percent of
businesses indicate that they have a reasonably well-documented and visible NPD process;
only 15.2 percent scored poorly.
3. An adaptable and scalable process: Is the NPD process a flexible one, adapted to the
needs, size and risk of the project? Or is it a rigid, one-size-fits-all process, failing to
recognize the difference between high risk and low risk projects? Two thirds of the
businesses in this study (80.6 percent) view their process as somewhat flexible, adaptable and
scalable. (The Best Performers score of 8.0 out of 10 compared to only 4.7 for worst
performers).
4. Whether the NPD is really used: The true test of a process is whether or not it is really
used; or is it merely window-dressing in the business (i.e. a paper process only). There is
clear evidence that some businesses have a process that is consistently used and understood
by the organization with 78.7 percent indicating a moderate or strong use of their NPD
process. Somewhat disturbing is that although the great majority does claim to have some
type of NPD process in place (only 11.9 percent claimed not to have a process at all), 21.4
percent claim that their process is not really used.
5. An enabling process for the project team: Another test of one’s NPD process is whether
or not it is a facilitating process that helps project teams get their products to market (rather
than a bureaucratic process that stands in the way). This is one of the weakest elements of
the NPD process, with a moderate mean rating score of 5.9 out of 10, and with 56.8 percent
reporting that the process is only moderately enabling (22.0 percent of businesses reporting
that it is strongly enabling). (However, best performers outscore the worst performers 7.2 vs.
4.1 out of 10.)
6. Defined Go/No Go criteria at gates: Go/Kill criteria are considered important to better
evaluate the merits of NPD projects, and to assist management in making the critical
Go/No Go decision. In spite of the logic of having such consistent gate criteria, the lack of
such criteria is fairly widespread (22.5 percent of businesses lack these criteria; only 43.1
percent claim to have very well-defined gate criteria). Indeed this is a somewhat weaker facet
of business’s NPD processes (a mediocre mean rating score of 6.6 out of 10). Without clear
decision criteria it is hard to separate the winning projects from the less attractive ones.
Interestingly, the best performers score twice as strong as the worst performers (8.6 vs. 4.3).
7. Deliverables defined for each gate: A menu of what the project team is expected to
deliver to each gate in the NPD process—their “deliverables”—is a positive feature of best-
in-class new product processes that is also common amongst the sample of businesses.
Overall, having well-defined deliverables is rated fairly strongly, with 84.6 percent of
businesses having such an explicit menu of deliverables to guide project teams.
8. Checks to monitor if the process is followed: Monitoring to see how well the process is
followed is a good way to determine if project teams are actually using the process. If too
many teams are not following the process, the checks can act as an early warning signal.
Unfortunately, the overall mean score reported here was 5.6 out of 10 with only 23.5 percent
of companies reporting that they are very good at monitoring the process.
Merely having a NPD process in place, however, is a good start but it is not enough to maintain the
position of a top performing company. Instead having a good process in place is really just the
starting point. The Best Performers go on to further enhance their process to ensure it is working
effectively and delivering the desired results. Unfortunately, the poorer performers still have not
adapted this best practice as the results in Figure 3.2 clearly demonstrate.
Some examples: As would be expected of best practice firms, companies that took part in the site visits
(the case studies) had in place a well designed stage-gate new product development process (e.g., Air
Products, Ashland, BD, ESI, and EXFO). A detailed profile of each company’s process is provided
in Appendix A. Each company indicated that a solid, well-defined process with clearly defined
activities in each stage and a well-defined decision framework for the gates (decision points) was a
critical best practice for them.
Air Products and Chemicals, Inc.: “The organization uses a consistent, organization-wide
process called offering development and introduction (ODI) that is modeled on the Stage-
Gate® process. This process, a company-wide stage-gate framework, has become
institutionalized and is ingrained in the language and culture of the company.”
Ashland, Inc.: “We have been able to successfully combine our product development
process [Stage-Gate] with our Six Sigma program. This combined approach allows us to
produce high-quality products in a disciplined manner.”
Becton, Dickinson and Company (BD): “BD’s global new product development system
serves as an effective baseline for planning and managing NPD projects and provides a basis
for functional transparency and accountability.”
NEW PRODUCT DEVELOPMENT
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Copyright © 2011 by Product Development Institute and APQC
New Product Development
P R OCE SS BE NC HMARK S AND PER F OR MANC E ME TRI CS
Electro Scientific Industries, Inc. (ESI): “The improved consistency of the process is
helping to improve the quality of content, accelerate learning for new participants, and
enable objective status reporting.”
EXFO: “We have a well-defined stage-gate process that over the years has evolved as we
have adapted to changing market needs. Our process is a considered an asset.”
The results from these and other firms have been impressive. For example, Michael Popule, Group
Manager, Reaction Engineering, Air Products when asked about the impact of their process, said “It
allows us to fail fast and move on rather than not try risky projects that could have a large reward.”
A closer look at the ingredients of such a process confirms the conclusion above: that having a new
product process is the starting point to separate the Best from the Worst Performers. Having all of
the elements of this process is very evident in top performing businesses. Note how high Best
Performing businesses rate on almost all the elements of a systematic NPD process in Exhibit 3.2
compared to the Worst Performers.
Best Performers’ NPD processes are enablers—they make it easier for project teams to drive
their NPD projects to market (rather than being a burden on them)
Best Performers’ NPD processes are adaptable and scalable—they are flexible processes,
adapted to the needs, size and risk of the project (rather than being a rigid one-size-fits-all
process, failing to recognize the differences between major and minor projects).
5.7
Use formal NPD process 8.1
9.2
5.7
Visible, documented process 7.6
8.4
4.7
Adaptable, scalable process 6.9
8.0
3.8
NPD process is really used 6.1 Worst Performers
6.8 Middle Business
4.1 Best Performers
Process enables project teams 5.9
7.2
4.3
Go/No Go criteria defined 6.6
8.6
5.1
Deliverables defined per gate 7.5
8.8
3.3
Checks to monitor process is followed 5.6
6.0
2 3 4 5 6 7 8 9 10
0=Not 10=Very
at all Impact of Each NPD Process Element much so
Conclusions: Overall, the majority of businesses fare very well in terms of their new product
processes. For the majority of businesses, the NPD process is in moderately good shape.
Best Performers overwhelmingly have a NPD process in place, along with most of its elements. Thus
having a NPD process, along with the items or ingredients listed in Exhibit 3.1, is highlighted as a
best practice in this study. So, if your business lacks a solid NPD process, or it’s only a high-level
process, it’s time to install a best-in-class process, complete with these eight items observed in our
Best businesses:
1. A clearly defined idea-to-launch new product process. This includes clearly designated
stages—a series of defined stages, for example: ideation, scoping, build the business case,
development, testing and launch; with activities defined for each stage (i.e. outlines of what
happens in each stage and includes guidelines on the “how tos”).
3. An adaptable and scalable process—a flexible process, adapted to the needs, size and risk of
the project.
4. A process that is really used. An effective implementation and ability to sustain the process is
essential: getting senior management buy-in and commitment (i.e. they really are walking the
talk); user-friendly documentation; training of all players—teams, team leaders, and
gatekeepers; ensuring all projects are in the process; a Process Manager in place; a process
database, IT support and performance metrics all contribute to ensuring the process is
enabling people and that they actually use it.
5. An enabling process for project teams—a facilitating process, helping project teams get their
products to market.
6. Defined Go/No Go criteria at gates—the criteria that projects will be judged on to make
Go/Kill and prioritization decisions.
7. Deliverables defined for each gate—a menu of what the project team is expected to deliver
to each gate meeting. This is often in the form of templates.
8. Monitoring the process to ensure it is really working. By ensuring that teams are actually
using the process and identifying where and or why they are not provides the continual
feedback needed to continue improving the process and making it “the way we do business”.
Note that merely having a formal and documented NPD process is only the first step. It is how the
process, its activities and recommended practices are implemented that makes the difference. We will
see some of these impacts later in this chapter.
Bureaucracy: It is also important to ensure that your process is constantly improving over time to
leverage internal learnings and to ensure if it is meeting both internal and external needs. Hence,
there is a need to be consistently on the alert for non-valued work or outdated documentation. You
need to get rid of any bureaucracy that may have entered into your process over time. Your NPD
process should be designed to facilitate project teams in getting their new products to market,
securing resources and senior management commitment, and removing roadblocks. Instead, too
many NPD processes, implemented with the best of intentions, appear to create bureaucracy and
much non-value-added work. One way to prevent this from occurring is to periodically review your
process to make any needed improvements. Most companies in the survey have revamped or
restructured their process:
Flexibility: Next, make sure that the process is flexible and scalable, perhaps having different versions
of the process—a full five-stage, five-gate process for major NPD projects, and perhaps a shorter
three-stage process or “Stage-Gate Express” for lower risk projects, such as enhancements,
modifications and extensions. One size does not fit all!
Most companies acknowledged that they do attempt to do these activities but there are significant
differences in how well each activity is actually conducted. These include:
1. Initial screening—the first decision to move ahead on a new product project. Often this idea
screen is handled by a mid-management group, and relies on criteria for making the Go/No
Go decision to allocate funds or people to the proposed new product idea.
4. Customer value assessment—determining the value of the product (or value-in-use) of the
proposed new product in the customer’s eyes.
Although no one group excelled at these key activities the best performing companies were
consistently able to do better quality work for each activity (see Exhibit 3.3). In other words these
organizations were able to conduct better quality of execution to derive better quality information on
the merits of undertaking a project before the actual development work began. There is a clear
emphasis on up-front homework: Up-front homework takes place—both customer and technical
assessments—before projects move into the Development Stage. This is probably one of the key
reasons why these better performing companies achieved the performance results highlighted in the
previous chapter.
4.6
Initial screening 5.8
6.8
5.0
Technical assessment 6.5
7.3
4.3
Manufacturing assessment 6.0
6.9
4.1
Customer value assessment 5.8
6.4 Worst Performers
Middle Business
5.0 Best Performers
Business analysis 6.6
7.4
3 4 5 6 7 8 9 10
0=Very What is the Quality of Each 10=Excellent
poor NPD Process Element
First let’s look at the use of gatekeepers in general. Sometimes it is unclear just who should undertake
project reviews and whose signatures are needed for a project to proceed. The locus of decision-
making—the people who make the Go/No Go decisions at gates—is also an important feature of
many firms’ NPD processes. In Exhibit 3.4 most companies clearly have identified gatekeepers or
decision makers. In some organizations these decision makers remain the same throughout the
process while others use more senior or higher level decision makers for later Gates that require
more resources and use the lower level gatekeepers for the earlier Gates. Best performing companies
tend to use the later approach more often, indicating that they reserve senior management time by
using mid-level decision makers for the early Gates (usually Gate 1 and 2) where fewer resources are
allocated. However some companies argue that it was better to keep a consistent set of gatekeepers
throughout the process.
6.0
Have designated Gatekeepers 7.6
8.1
2.8
Gatekeepers change as risk changes 4.2 Worst Performers
5.5 Middle Business
Best Performers
4.3
Go/No Go criteria 6.6
8.6
5.1
Defined Gate deliverables 7.5
8.8
2 3 4 5 6 7 8 9 10
10=Very
0=Not Presence of Each NPD much so
at all Process Element
Next, defined Go/Kill criteria are considered important to better evaluate the merits of projects, and
to assist management in making the Go/No Go decision. In spite of the logic of having such gate
criteria that are spelled out for each gate (written down and visible to everyone), the lack of such
criteria is fairly widespread amongst the poorer performing organizations (4.3 out of 10 compared to
8.6 for best performers). Thus, best performers were twice as likely to have clear Go/Kill criteria as
worst performers.
Finally, for gatekeepers to be able to make good decisions and apply decision criteria, it is helpful to
have the right information available to aid in making these decisions. Top performers tended to have
deliverables clearly defined for each gate. A standard list of items that the project team is expected to
deliver to each gate in the process—their “deliverables”.
In summary, best-in-class new product processes have clearly designated gatekeepers with clear
Go/No Go decision criteria and predefined deliverables identified. Interestingly, when probed about
global gatekeepers that have oversight for projects spanning multiple geographic locations the results
were mixed with 46.9 percent of companies indicating that they were moving in this direction but
53.1 percent did not use this approach.
Having the gate structure in place is, in itself, not enough however. It is also important to ensure that
these meetings are effective: that the meetings are held; that the right people attend; that the
discussion and decisions are of high quality and even that the decisions are actually made. If the
meetings are well run and are producing good quality decisions, then the people will see these
meetings as a productive and efficient way to handle this type of decision-making. So how does our
sample of companies measure up? Interestingly most organizations indicate that this was an area that
could be improved upon. However both the moderate and best performers were well ahead of the
poor performers in how they practice the Gate principles (the results are illustrated in Exhibit 3.5):
1. Gatekeepers attend the meetings: All of the key decision makers invited to participate as
gatekeepers attend the gate meeting. There are no cancellations, if at all possible, and when a
cancellation does occur by one individual the meeting still goes ahead.
2. Effective Gate meetings: The meetings themselves are managed effectively. Agendas are
distributed in advance, meetings start and end on time, the agenda is followed and a record
of all decisions is kept. In other words good meeting protocols are developed and followed.
3. High quality contribution: Each gatekeeper makes good quality contributions. In order
for this to occur, each gatekeeper comes prepared for the meeting and has pre-read the
project materials. The questions are insightful and helpful to understanding the risk
associated with the project. (Note this was the weakest area for the poor performers).
5. Decisions are actually made: Decisions are made at each gate meeting. Either a
Go/Kill/Hold/Recycle decision, including approval of the action plan for the next stage of
work and approval of the resources and date for the next meeting.
6. Gatekeepers support the decision: Each gatekeeper visibly supports the decision made at
the gate meeting (including resources) in the weeks or months after the meeting. This was
the highest score of this category by the best performers (7.1 out of 10).
4.7
Gatekeepers attend meetings 6.1
6.2
4.9
Effective gate meetings 6.4
6.9
3.0
High quality contribution 5.6
5.9
3.6
Quality/objective decisions 5.8
6.7
3.9
Decisions are actually made 6.5
6.9 Worst Performers
Middle Business
3.7 Best Performers
Gatekeepers support decision 6.0
7.1
3 4 5 6 7 8 9 10
0=Not How Effective is Each Gate Principal 10=Very
at all much so
2. Deliverables are distributed on time: All agreed-upon deliverables are distributed to the
gatekeepers on time. Hence the deliverables are received on time, reviewed for completeness
and distributed to the gatekeepers per the guidelines in the NPD process. Note that this was
the weakest score for the poor performers (4.1 out of 10).
3. Business case is of high quality: The business case and/or executive summary that are
submitted to the gatekeepers are of high quality. That is, they are complete, include accurate
information, add value, and focus on the critical issues.
4. Gate presentation is of high quality: The presentation made at the gate meeting is of high
quality. It is concise, within the allotted time period, includes a clear recommendation with
options/alternatives, action plan for the next stage of work, and has a clear request for
resources.
3 4 5 6 7 8 9 10
0=Not 10=Very
at all Quality of Gate Deliverables much so
Other common warning signs that you may have poor governance practices are:
1. Inefficiencies occur due to duplication of effort. Without good co-ordination and approval, your
projects and project teams from around the world are very often working on similar projects,
or even worse, the same project, without realizing it. Oversight of the innovation pipeline
helps to ensure that different parts of your company—often with good intentions—are not
duplicating each other’s efforts.
2. Decision making is not clear and is lacking in accountability. Who is responsible for a project and
how an approval is gained should not be guesswork or the result of hallway lobbying efforts.
As good projects surface in your business, a clear path should exist to secure timely
approvals. For this to happen, clear accountability and a clear specification of who should be
making these types of decisions are needed.
3. The right decisions are not being made. The information to make effective investment or Go/Kill
decisions is often missing or not available. A common symptom here is the uneasy feeling
that your development pipeline contains too many projects that should be killed, and that it
lacks the type of projects needed to meet your business goals.
4. Resource deployment is not clearly aligned with your business’s strategy. Although your people are
working hard and have a full plate of projects to work on, there is no assurance that these
efforts support the strategic direction of your business. This is likely the result of weak
guidelines that lack clear decision criteria.
5. Frustration over the value of the innovation pipeline. Here a common symptom is the feeling that, if
all projects in your pipeline were completed, they would not meet desired targets. It is
probably full of time-consuming, yet low value projects. Or, worse yet, there are no realistic
valuations on projects. Hence there is no real control and prioritization.
6. Business units are not following a governance process to manage innovation. The problem here is that
each business unit spends R&D resources or consumes corporate R&D budgets, but does
not utilize a proper and standard approach to selecting and funding projects; or they have no
clearly defined innovation strategy. Without this type of oversight, it is very hard to have
confidence in the business unit’s ability to deliver results against their strategic plans.
7. Decisions are not timely. Your competitors always seem to be ahead of you and, as a result, your
project teams always seem to be racing to catch up. With a poorly managed innovation
strategy, organizations do not fund their strategic buckets properly. Instead, they are busy
supporting short-term market requests from the sales teams. Hence, no balance exists
between incremental product development projects and longer term, more strategic, major
projects.
8. Internal politics play too large of a role. We have all been there. More time is spent lobbying than
actually doing real work. With no clear definition of roles and responsibilities, your people
learn how to work the system to get things done. So a large amount of their time is spent
lobbying to get or keep their budgets and people.
9. A lack of visibility regarding decision making. No one can really explain how to get approvals or
how past projects were approved. Good projects lie fallow, while others seem to have a life
of their own.
10. Frustration around the level of bureaucracy. Your people’s frustration with the level and degree of
bureaucracy is often a warning sign that existing polices and supporting documentation
requirements are actually counterproductive. Stifling innovation with too much bureaucracy
is very easy, particularly in a large organization. While some policies and procedures are
needed, companies today are too lean to support unnecessary work.
The team composition is cross-functional from different functional areas such as R&D,
Marketing, Operations, Supply Chain, etc. as needed.
These teams work to resolve specific problems and to perform tasks related to the project.
Top performers are much better at this than poorer performing companies (8.5 vs. 5.9 out
of 10).
There is a clearly identified team leader—a person who is in charge and responsible for
driving the project.
The in-depth case studies that were conducted highlight a number of best practices that these
companies use to leverage their teams for more successful outcomes. Here is a summary of the key
findings from these case studies that are presented in more detail in Appendix A:
Each project is assigned team members that represent the cross-functional needs of the
project
Key team members tend to remain with the project from start to finish
Cross-functional cooperation and communication is good
The assigned project team is accountable for the performance of the project
Teams are able to handle outside-the-team inputs and decisions effectively and have an
executive sponsor to help when necessary
The team leader can be from any functional area however it is more common to see these
team leaders as professional project leaders with the proper training
Technology is leveraged so the team members can communicate effectively. This is more
important when teams are not co-located such as in regional or global project teams.
Other 1.9%
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