The Product Development Process – From Idea To Production

The Product Development Process - Chapter 1 of 6 - An overview and process flowchart showing the development path for a new product from idea through design, development, and into production.

What Is Product Development?

Creating a new product is so much more than making a few parts.  It happens through a process we call "Product Development."

Have you ever heard questions like:  "How do I get my great idea to market?"  or  "I have this invention, now what should I do?"  They are excellent questions.  The not-so-simple answers come as we move on the path of defining and designing the new product.

The flow of the product development process is not difficult to understand, though some of the details can be more involved.  That is the purpose of this guide.  The flowchart below provides a map of the process, while the following chapters explore each step in more detail.

While every product will follow a unique path through development, the primary flow is the same, and each step builds on the last.  Experience shows the value of staying on course - especially with the early definition and planning steps - to avoid expensive backtracking later.

From the Author:  These chapters share lessons learned while helping both people and companies bring hundreds of products to market.  We cover many of the common questions and misconceptions about "What should I do next?" along the development path from an idea toward a valuable product.

The Product Development Flowchart

Let's start with a graphic, a process flowchart – we will call it a map.  We could illustrate it in a number of different ways, but this one is easy to follow and to connect the steps with each of the chapter pages.

The Product Development Process

	Step 1 – Identify the "Bright Idea" (See notes below.)
	Step 2 – New Product Requirements / Engineering Specification Documents to stay on track   Step 3 – Gather Info & Product Planning Patents? Market Research, Business Plan
	Step 4 – Product Design, Refinement, and Engineering Science, Art, CAD, Analysis, DFM
	Step 5 – Prototypes & Testing Verify, Prove, Test, Learn Feedback to steps above   * Iterate until ready for production.
	Step 6 – Manufacturing / Production Details, Instructions, Tooling, Packaging, and much more

 
This process flowchart leaves out many details that we will fill in chapter by chapter.  For now, please know that it is not as simple as the diagram shows, AND it is not as overwhelming as some people make it sound.

The Product Development Process is not linear as suggested by the illustration, yet for the flowchart it is easier to visualize that way.  In a real path there will be back and forth, up and down.  For instance, Step 2 is "Defining Requirements", but there is no way to know all the requirements prior to getting more deeply into other areas like design and preparing for manufacturing.

Also, Prototyping can show us things as new requirements too – or change how we view what we need (or don't need) in the design, or in a patent.  The true map is messy, but don't worry, it does not feel that way when you are in it.

All along through the process we will learn.  Learning about the new product, and what the customer really wants.  Also, learning about manufacturing and what it takes to make our new product.  The development process is encompassing, so learn all you can.

See the various links to all the Product Development Process chapters.  Or, follow along step by step using the "Next" links at the bottom of each chapter, and in the flowchart.  Additionally, there are insight pages with this guide for even more education.

Additional Insights For Product Development

Engineering Process Notes		When to Patent? Why Patents?		Protecting Your Big Idea

 
Use all of these materials to help on your product development journey.  If you are ready, let's get started.

Step 1 – Start With The Bright Idea

Identify
the "Bright Idea"
(Step 1)

Your "Bright Idea" is the magic that sets things in motion.  It sits right at the top of the flowchart.  If you have that great idea, and you want to turn it into a useful product, you are on the right track.

Discovering the "Bright Idea" is the first big step, and it usually occurs without much of a method.  Not every bright idea is an invention.  Sometimes updating an existing product to make it better is the bright idea.  Sometimes it is an expansion of your product line to fill a need your customers have.  All of these are treated the same for this Product Development guide.  They all start with the idea, then need the product development process if they are going to be great products someday.

This step also includes refining notions around the idea - improving and finessing the concepts - perhaps weeding out competing ideas - until you think the idea you have has merit.  Refining is a mental exercise of challenging the ideas, thinking about how you can make it better, and ways that it will fail.

As you think about it, and talk with other people about it, you can mutate it until it is great.  We have a lot more on refinement in the article about learning from critics.

Once the idea has merit, advancing it and solidifying the details is the work of the remaining Product Development Process steps.

Applying The Product Development Process

There are many considerations that come together in the Product Development Process.  It is a process of thinking through issues, working out details, finding compromises, then launching production.  It includes deciding how the product will look and function, how it will be manufactured, what materials to use, potential failure modes, applicable regulations, and intellectual property protection.

Ah, but don't get overwhelmed.  The exact path is different for every product, while the same fundamental development principles apply.

The six steps in this guide provide a framework rather than a rigid recipe.  It is generic enough to cover a wide range of new ideas and products, yet specific enough to guide each project in a unique course.

Use this guide to examine the many things that go into the process.  As you add your specifics to our generic outlines, the process will become uniquely yours.

To facilitate discussion we will use an example of the Product Development Process in action.  When you see this shaded box, it is an illustration of the steps.

For more product development examples, see our Product Design and Development work samples and the Engineering Case Studies in the Library.

Learning with This Guide

A simplified flowchart of the Product Development Process is shown graphically above.  Take your time with each chapter.  They all have good information as you plot your course, on your unique path.  Take notes.  Capturing your thoughts is a great way to make sure you are happy with the final product.

Earlier versions of this guide have been used, by permission, in educational materials by some colleges.  For you it is a free reference for education in your own product development adventure.

Step 2 is next – defining what the product must be and the requirements that will guide its development.

Next Up: Chapter 2 - Defining New Product Requirements