lean management methods in product development – a case study
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Lean Management Methods in Product Development – A Case Study Advances in Sustainable and Competitive Manufacturing Systems Lecture Notes in Mechanical Engineering 2013, pp 1385-1399. 23rd International Conference on Flexible Automation & Intelligent Manufacturing (FAIM 2013) http://link.springer.com/chapter/10.1007%2F978-3-319-00557-7_112 Daniel Soares 1, João Bastos 2,3, Diana Gavazzo 1, João Paulo Pereira 1 and A.J. Baptista 1 1 INEGI – Instituto de Engenharia Mecânica e Gestão Industrial Faculdade de Engenharia da Universidade do Porto Porto, Portugal 2 INESC TEC Faculdade de Engenharia da Universidade do Porto Porto, Portugal 3 ISEP Instituto Superior de Engenharia do Instituto Politécnico do Porto Porto, Portugal ABSTRACT The current reality of intense competition has forced many companies to increase their performance and competitive advantages by pursuing innovation and improving and streamlining internal methods of designing products and processes. With shortening of product life cycle, in order for companies to survive, the need for a continuous stream of multiple innovations over time has arisen. However, the resources consumed by companies, whilst developing a product or process, are increasingly high, even in integrated approaches, and often the finished product or process arrives too late to provide the company with an edge over its competitors. Due to the large impact Lean philosophy has had in recent decades, within the manufacturing area, through the increase of efficiency and generation of continuous improvement, more companies have progressively applied Lean methods in their units of product and process development. This paper seeks to present a reference model for Lean implementation in the areas of product and process development in order to support companies in their path to streamline and make their innovative processes more efficient. The proposed reference model includes a concrete case study example that helps to explain the main concepts behind the proposed approach.TRANSCRIPT
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Daniel Soares1, João Bastos2,3, Diana Gavazzo1, João Paulo
Pereira1 and A.J. Baptista1
Lean Management Methods in
Product Development – A Case Study
1 INEGI – Instituto de Engenharia Mecânica e Gestão Industrial2 INESC TEC – Instituto de Engenharia de Sistemas e Computadores do Porto3 ISEP – Instituto Superior de Engenharia do Porto
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CONTENTS
1. Introduction
2. Lean manufacturing vs Lean product development
3. Reference model development
4. The “stopper” concept in the PDCA cycle
5. Implementation examples
6. Results and final considerations
Lean Management Methods in Product Development
A Case Study
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1. Introduction
Top Management Commitment
Lean Management Methods in Product Development
A Case Study
Difficulties of Lean Implementations and Continuous Improvement
� The (common) human resistance to change
“Making Change Work: Practical Tools for Overcoming
Human Resistance to Change” Book by Brien Palmer
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1. Introduction
Lean Management Methods in Product Development
A Case Study
Difficulties of Lean Implementations and Continuous Improvement
� Have an accurate assessment of the “AS IS” (initial) state
Visible components of the system
� Processes
� Procedures
� Tools
Invisible components of the system
� Culture
� Behaviours
� Mentality
� Habits
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2. Lean manufacturing vs lean product development
Lean Management Methods in Product Development
A Case Study
Manufacturing
� Visible flux of materials and WIP
� Easier identification of wastes
(stocks, WIP, disorganization,
bottlenecks, failures, etc.)
� Repeatable tasks and processes
Product Development
� Invisible flux of data and
information
� More difficult to identify waste
(over-engineering, poor
knowledge management, slow
access to information, etc.)
� Strong process variability (less
repetitive tasks)
Ability to influence teams
productivity and the customer
defined value and costs Ability to influence product
quality, operation costs and
productivity
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3. Reference model development
Lean Management Methods in Product Development
A Case Study
Culture of the organization
Supportive Management
Improved Quality – Reduced Cost
Reduced Lead Time – Improved Security – High Morale
Lean Management
Re
spe
ct f
or
Hu
ma
nit
y
Co
nti
nu
ou
s
Imp
rov
em
en
tInformation
flows
• Clear
• Accurate
• At the right time
Value
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4. The “stopper” concept in the PDCA cycle
Time
Imp
rove
me
nt
Standardization stable levels
(classic lean approach)
Lean Management Methods in Product Development
A Case Study
An “anti-rollback mechanism” during change transition
Objectives
� Analyse failure modes or
weaknesses for the process
improvement implementation
� Find intrinsic motivation within
the team for the change
� Avoid unpredicted issues for
the change before it happens
� Secure the improvement
progress until the complete
standardization stable level
Change transition
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Respect for Humanity: Skills and intrinsic motivation matrix
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Respect for Humanity: Skills and intrinsic motivation matrix
Objectives
� Get a information about each team
member Skills (Self Evaluation) and
hidden talents
� Get a information about each team
member intrinsic motivation (Self
Evaluation)
� Match adequate team member skills for
the project and which he/she is more
motivated for those technical areas
� Detect insufficient technical capabilities
within the team
� Manage team knowledge more
effectively both for projects and training
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
Problems
� Get to know for the entire team
useful and essential information
(technical or general)
� Avoid long time waste searching
information and long clicking
sequences
� Avoid resistance and blocking
attitudes for folder directory re-
organization by 5S tool application
Objectives
� Aggregate and compile
information at “one click distance”
� Create a visible link for a digital
box of suggestions and issues
reporting
� Create an robust and simple
method to change file folder
systems organization without
impact normal day work
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5. Implementation examples
SF3
SF2
SF1
Main Folder
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
SubFolder 1
SubFolder 2
SubFolder 3Target File
Target File
Spaghetti line length - elapsed time
Main Folder
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5. Implementation examples
SF3
SF2
SF1
Main Folder
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
SubFolder 1
SubFolder 2
SubFolder 3Target File
Target File
Ideal Solution = Direct way
Main Folder
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
“Real world inspiration”: temporary bridge
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
“Digital inspiration”
Invisible meta data linked to organized visible icons
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
Stoppers: Use of wide spread Power Point software and attractive features for the team (both technical and for social team integration)
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Overcoming information access issues and time waste burden
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5. Implementation examples
Lean Management Methods in Product Development
A Case Study
Other issues and implemented solutions
� Standardized Project Folder Structure (reduced time for new project members)
� Standardized file name convention
� Technical Library re-organization (with Endnote, more than 1000 files catalogued)
� List of contacts (team members, clients, suppliers)
� List of suppliers capabilities and evaluation by technical areas
� Development of advanced timesheets for time and task control
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6. Results and final considerations
Lean Management Methods in Product Development
A Case Study
� Development of an adapted Reference Model for Lean Implementations in
Product Development Projects
� Development of conceptual strategies for dealing with the change process
� Lean thinking and continuous improvement introduction within the team
� Centralization and broad availability and awareness of essential and useful
information for the team
� Standardization of name convention for files and folders (documental management)
� Identifying team technical skills weakness, hidden talents and knowledge level
� Increased motivation of team members by knowing and using their intrinsic
motivations and opinion (suggestions and issues reporting)
� Estimated gains of 2300 hours / annum (within a 15 elements group)
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Daniel Soares1, João Bastos2,3, Diana Gavazzo1, João Paulo
Pereira1 and A.J. Baptista1 [[email protected]]
Lean Management Methods in
Product Development – A Case Study