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Integrating Plan for Every Part Analysis with Bill of Materials Readiness to Mitigate Long Lead-Time Risk in New Product Introduction

Chidera A. Ebisi, Ngodoo Joy Sam-Bulya

Abstract

Long lead-time components can threaten a new-product launch even when the bill of materials appears complete. This paper develops a stage-gated framework joining Plan for Every Part analysis with bill-of-materials and enterprise-system readiness. A shared part-level record combines supply lead time, internal release lag, required build dates, evidence status and criticality. Lead-time slack and a weighted Material Readiness Index support explicit gate decisions and recovery ownership. A composite power-systems launch with 214 bill-of-materials lines demonstrates how timing and data readiness can produce different risk assessments. The example illustrates the decision logic without estimating its effect on launch performance. Buffer values, weights and gate thresholds are design parameters that require calibration and sensitivity analysis. The contribution is a traceable bridge between part-level planning and launch governance, with documented exceptions rather than an assumed readiness guarantee. Multi- program validation should test the relationship between gate assessments and shortage hours, expedite cost and schedule adherence. The framework complements quality planning, process capability and supplier qualification.

Keywords

new product introduction; Plan for Every Part; bill of materials; ERP master data; lead-time risk; stage-gate; material readiness; supply chain resilience; U.S. manufacturing; power systems manufactur

References

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