Lean product development implementation

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Simple tools how to implement lean product development

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  • 1. LEAN Product Development Implementation Itzhak Ben-Levy - LEAN Expert itzhak@benlevy.co.il www.benlevy.co.il August 2012Itzhak Ben-Levy LEAN Expert 1
  • 2. The Traditional way It is Too many parts expensive Nobody gave me The target cost I cant assemble it The requirements were changedItzhak Ben-Levy LEAN Expert 2
  • 3. The Development Problems Long development cycle times Many redevelopment cycles High development costs Long production cycle times High production costsItzhak Ben-Levy LEAN Expert 3
  • 4. LEANLEAN Manufacturing LEAN Product DevelopmentItzhak Ben-Levy LEAN Expert 4
  • 5. 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 communicationItzhak Ben-Levy LEAN Expert 5
  • 6. LPD workshopItzhak Ben-Levy LEAN Expert 6
  • 7. Outcome of LPD workshop Reducing development production lead time and cost by: 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 actionsItzhak Ben-Levy LEAN Expert 7
  • 8. Itzhak Ben-Levy LEAN Expert 8
  • 9. Value to the customer Solving customer Problems Exploiting Opportunities The product should Look good The Customer should Feel good 9Itzhak Ben-Levy LEAN Expert 9
  • 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 10Itzhak Ben-Levy LEAN Expert 10
  • 11. NPI - New Product Introduction IPT METHODOLOGIES (Integrated Product IPT Leader - Project Manager Team) System Engineering QFD Logistics REUSE Production Engineering DFMA Contracting PROCESS MAPPING Customer PHASE DTC Strategic Suppliers Finance MAKE-BUY GATE Planning RISKS MITIGATION Customer Service ARO Design Readiness DRR MANAGEMENT PLAN RISKS PRODUCTION & SPEC REQUIREMENTS CONFIGURATION DEVELOPMENT POLICY TECHNOLOGIES DEVELOPMENT PROTOTYPE PROGRAM PURCHASING PERFORMANCE MATERIAL RESOURCES TIME TABLES ARCHITECTURE ENVIRONMENT COMPONENTS MANPOWER ORGANIZATION CHART REUSE INFRASTRUCTURE BUDGET PLAN TESTS MAKE-BUY TARGET COSTS CUSTOMER QUALITY ILS SUB CONTRACTORS DEVELOPMENT REQUIREMENTS PRODUCTION CUSTOMER DELIVERIES MAINTAINABILITY LCC PRODUCT TESTS OUTPUTS DEVELOPMENT TOOLSItzhak Ben-Levy LEAN Expert 11
  • 12. 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 INSPECTIONItzhak Ben-Levy LEAN Expert 12
  • 13. DTC PRICE - PROFIT = COST Determined by the competitors Determined Determined by the to the project corporate managerItzhak Ben-Levy LEAN Expert 13
  • 14. How the engineer now how ?to design Sub contracting riveting casting welding forging machining The cost target determined itItzhak Ben-Levy LEAN Expert 14
  • 15. Reduce requirements And cost Requirements (QFD) challenge Accept all Important Consider to delete Not delete Implementation important Cost High (DTC) LowItzhak Ben-Levy LEAN Expert 15
  • 16. Suppliers costs reduction Supplier Engineering Costs drivers Requirements PrioritiesCost Reduction Requirements ReductionItzhak Ben-Levy LEAN Expert 16