lean product development implementation
DESCRIPTION
Simple tools how to implement lean product developmentTRANSCRIPT
1 Itzhak Ben-Levy LEAN Expert ©
LEAN Product Development
Implementation
August 2012
Itzhak Ben-Levy - LEAN Expert
www.benlevy.co.il
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
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The Development Problems
• Long development cycle times
• Many redevelopment cycles
• High development costs
• Long production cycle times
• High production costs
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LEAN
LEAN Manufacturing
LEAN Product Development
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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
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LPD workshop
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• 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:
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Value to the customer
• Solving customer Problems
• Exploiting Opportunities
• The product should Look good
• The Customer should Feel good
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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
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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
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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
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DTC
COST = PROFIT - PRICE
Determined
by the
corporate
Determined
by the
competitors Determined
to the project
manager
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How the engineer now how
to design?
casting welding
machining forging
Sub
contracting riveting
The cost target determined it
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Not
important
Important
Low High
Requirements
(QFD)
Accept all
Consider to
delete delete
challenge
Implementation
Cost
(DTC)
Reduce requirements And cost
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Engineering
Requirements Reduction Cost Reduction
Supplier
Suppliers costs reduction
Costs drivers
Requirements
Priorities