PureSole – Organization and series launch

PureSole is one of the largest development products in foot orthopedics in recent years. But before the new blanks can be produced, it is necessary to define processes, approve materials, prepare documentation and safeguard manufacturing workflows. Doreen Selz handles these particular interfaces. As an employee in Launch Management, she helps to oversee the transition for new products to series production and makes sure that development ultimately results in a stable series product.

When does your work begin in the development process?

Doreen Selz: I am closely involved starting with the C sample phase. This concerns the product that is ready for series production. As development maturity progresses, we take on responsibility for the production launch. This is followed by pilot lots and step-by-step release of the individual models. In the process, we check whether the products can be reliably manufactured for series production in varying sizes, and whether any more adjustments are needed.

What does that mean specifically for a project like PureSole?

Doreen Selz: Various sizes need be produced and evaluated for each model. Once these pilot lots are successfully concluded, then we start with the actual launch volume. Overall, we are taking about several thousand foot orthoses here which need to be produced in addition to ongoing daily operation. That shows the kind of dimensions this project has come to occupy.

What divisions are you collaborating with?

Doreen Selz: Many different areas. Product management, development, purchasing, work preparation, master data, product controlling, RAC, production and quality management: every division has its own responsibilities within the project. Our job is to bring together the different threads and make sure that all the information comes together.

What was particularly challenging on PureSole?

Doreen Selz: The magnitude of the project. We’re not taking about one or two new products, but more than 30 new models. This hugely increases the coordination effort required. Topics like material procurement, documentation, master data maintenance, work instructions or the impact of changes are easy to underestimate. With this number of models, that turns into a real challenge.

What work is invisible at the end even though it’s decisive for the success of the project?

Doreen Selz: Communication and documentation, without a doubt. Many decisions are established in meetings or brief coordination sessions. If this information is not recorded clearly and passed on, it will be lost. That’s why we are very consistent about documenting responsibilities, dates and decisions. No one sees this later on with the finished product, but it’s decisive for ensuring that a project can be implemented successfully.

Were there situations where you needed to intervene?

Doreen Selz: Yes, that’s part of the process. Our job is also to check not only whether a product is functional, but also whether it will be feasible for stable, fault-free serial production later on. For specific models, we determined that certain material combinations were too critical in the serial process. In such cases, it is necessary to make decisions and potentially make adjustments or discard variants.

“It’s never too early to start talking to one another.”
Doreen Selz, Launch Management Team Foot Orthopedics

What have you learned from this project that you will bring to the table for future developments?

Doreen Selz: Above all, the importance of communicating early on. It’s never too early to start talking to one another and scrutinizing key topics. Many aspects seem secondary at the beginning – like material designations, documentation requirements or responsibilities. But these details can turn out to be decisive later on. These experiences will help us on future projects. Ultimately, it is important to learn from mistakes and not repeat them.

What is your outlook on foot orthopedics in the coming years?

Doreen Selz: Very positive. We are seeing that many new projects are being created, and there continues to be investment and growth in foot orthopedics. At the same time, our processes are also being further developed. Since April, my focus has been entirely on transitions and project work. This shows how important new products and launching them successfully will be in the future. And one thing is certain: PureSole will not be the last major project.

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PureSole – Organization and series launch

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