lean product development implementation

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1 Itzhak Ben-Levy LEAN Expert © LEAN Product Development Implementation August 2012 Itzhak Ben-Levy - LEAN Expert [email protected] www.benlevy.co.il

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Page 1: Lean product development implementation

1 Itzhak Ben-Levy LEAN Expert ©

LEAN Product Development

Implementation

August 2012

Itzhak Ben-Levy - LEAN Expert

[email protected]

www.benlevy.co.il

Page 2: Lean product development implementation

2 Itzhak Ben-Levy LEAN Expert ©

The Traditional way

I cant assemble it

Too many parts It is

expensive Nobody gave me

The target cost

The requirements

were changed

Page 3: Lean product development implementation

3 Itzhak Ben-Levy LEAN Expert ©

The Development Problems

• Long development cycle times

• Many redevelopment cycles

• High development costs

• Long production cycle times

• High production costs

Page 4: Lean product development implementation

4 Itzhak Ben-Levy LEAN Expert ©

LEAN

LEAN Manufacturing

LEAN Product Development

Page 5: Lean product development implementation

5 Itzhak Ben-Levy LEAN Expert ©

The main Principles Of

Lean Product Development

• Establish customer-defined value

• Front-load the product development

process

• Create a level product development

information flow

• Organize to balance functional expertise

and cross-functional integration

• Align your project through simple visual

communication

Page 6: Lean product development implementation

6 Itzhak Ben-Levy LEAN Expert ©

LPD workshop

Page 7: Lean product development implementation

7 Itzhak Ben-Levy LEAN Expert ©

• Templates for capturing new data and information

• A focus on value creating activities

• New insights into the development process

• Real time reallocation and synchronization of

activities

• Team identity and emotional commitment

• Common language among team members

• To do list identifying new corrective actions

Outcome of LPD workshop Reducing development production lead time and cost by:

Page 8: Lean product development implementation

8 Itzhak Ben-Levy LEAN Expert ©

Page 9: Lean product development implementation

9 Itzhak Ben-Levy LEAN Expert © 9

Value to the customer

• Solving customer Problems

• Exploiting Opportunities

• The product should Look good

• The Customer should Feel good

Page 10: Lean product development implementation

10 Itzhak Ben-Levy LEAN Expert © 10

QFD shorten cycle time by:

1. Understanding value to the customer

2. Exploiting customer needs

3. Deriving and consolidation of the

requirements from customer needs

4. Prioritizing requirements

5. Allocating requirements to the project

team

Page 11: Lean product development implementation

11 Itzhak Ben-Levy LEAN Expert ©

Design Readiness

QFD

REUSE

DFMA

PROCESS MAPPING

DTC

MAKE-BUY

RISKS MITIGATION

IPT Leader - Project Manager

System Engineering

Logistics

Production Engineering

Contracting

Customer

Strategic Suppliers

Finance

Planning

Customer Service

MANAGEMENT PLAN

PRODUCTION &

DEVELOPMENT

PURCHASING

TIME TABLES

ORGANIZATION CHART

BUDGET PLAN

CUSTOMER

REQUIREMENTS

CUSTOMER DELIVERIES

PRODUCT TESTS

DEVELOPMENT TOOLS

DEVELOPMENT POLICY

PROTOTYPE

MATERIAL

COMPONENTS

REUSE

MAKE-BUY

SUB CONTRACTORS

ARO

SPEC REQUIREMENTS

CONFIGURATION

PERFORMANCE

ARCHITECTURE

ENVIRONMENT

TESTS

QUALITY

ILS

MAINTAINABILITY

DRR

RISKS

TECHNOLOGIES

PROGRAM

RESOURCES

MANPOWER

INFRASTRUCTURE

TARGET COSTS

DEVELOPMENT

PRODUCTION

LCC

IPT (Integrated Product

Team)

OUTPUTS

METHODOLOGIES

GATE PHASE

NPI - New Product Introduction

Page 12: Lean product development implementation

12 Itzhak Ben-Levy LEAN Expert ©

LPD Gates

1. SRR – SYSTEM REQUIREMENT REVIEW

2. DRR – DESIGN READINESS REVIEW

3. PDR – PELIMINARY DESIGN REVIEW .

4. CDR – CRITICAL DESIGN REVIEW.

5. TRR – TESTS READINESS REVIEW

6. TRDR– TEST RESULT DESIGN REVIEW

7. PRR– PRODUCTION READINESS REVIEW

8. FAI – FIRST ARTICLE INSPECTION

Page 13: Lean product development implementation

13 Itzhak Ben-Levy LEAN Expert ©

DTC

COST = PROFIT - PRICE

Determined

by the

corporate

Determined

by the

competitors Determined

to the project

manager

Page 14: Lean product development implementation

14 Itzhak Ben-Levy LEAN Expert ©

How the engineer now how

to design?

casting welding

machining forging

Sub

contracting riveting

The cost target determined it

Page 15: Lean product development implementation

15 Itzhak Ben-Levy LEAN Expert ©

Not

important

Important

Low High

Requirements

(QFD)

Accept all

Consider to

delete delete

challenge

Implementation

Cost

(DTC)

Reduce requirements And cost

Page 16: Lean product development implementation

16 Itzhak Ben-Levy LEAN Expert ©

Engineering

Requirements Reduction Cost Reduction

Supplier

Suppliers costs reduction

Costs drivers

Requirements

Priorities