lean product development (lpd)

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1 Itzhak Ben-Levy LEAN Expert LEAN Product Development ( LPD ) October 2012 Itzhak Ben-Levy - LEAN Expert 972-523579166 [email protected] www.benlevy.co.il

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LEAN Product Development (LPD). Itzhak Ben-Levy - LEAN Expert 972-523579166 [email protected] www.benlevy.co.il. October 2012. Lean Definition. " A systematic approach to identifying and eliminating Waste through continuous improvement ". Lean is about our people – - PowerPoint PPT Presentation

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Page 1: LEAN Product Development (LPD)

1Itzhak Ben-Levy LEAN Expert ©

LEAN Product Development(LPD)

October 2012

Itzhak Ben-Levy - LEAN Expert972-523579166

[email protected]

Page 2: LEAN Product Development (LPD)

2Itzhak Ben-Levy LEAN Expert ©

"A systematic approach to identifying and eliminating Waste through continuous improvement "

Lean Definition

Lean is about our people – Train them, Empower them, Trust them,

Motivate them, Engage them

Page 3: LEAN Product Development (LPD)

3Itzhak 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 (LPD)

4Itzhak Ben-Levy LEAN Expert ©

In The BoxOut Of The Box

What is the best way to understand what is going on?

Each one Separately see

Part of the picture

Everyone see together all

the picture

Page 5: LEAN Product Development (LPD)

5Itzhak Ben-Levy LEAN Expert ©

LEANLEAN Manufacturing

LEAN Product Development

Page 6: LEAN Product Development (LPD)

6Itzhak 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 7: LEAN Product Development (LPD)

7Itzhak Ben-Levy LEAN Expert ©

IPT PRINCIPLES

• Focus on a product

• Multidisciplinary team

• Co - location

• Team working

Page 8: LEAN Product Development (LPD)

8Itzhak Ben-Levy LEAN Expert ©

IPT Integrated Product Team

Engineering

StressManufacturi

ngQuality &System Safety

Production

IPT Leader

SUPLIER

Analysis

CUSTOMER

Ron

Bill

RonnyDanSamGil

Neb

Roth Bob

Page 9: LEAN Product Development (LPD)

9Itzhak Ben-Levy LEAN Expert ©

LPD principle

TOOLS LEAN

FACILITATOR

IPT

PROJECT MANAGERLPD workshop

LPD TOOL

TO DO LIST

Just Do It!

Page 10: LEAN Product Development (LPD)

10Itzhak Ben-Levy LEAN Expert ©

Workshop TO DO LISTN° PROBLEM / ISSUE / OPPORTUNITY COUNTERMEASURE / EXPECTED RESULTS START COMPLETERESPONSIBLE STATUS

Project : Team Leader: DATE :

Page 11: LEAN Product Development (LPD)

11Itzhak Ben-Levy LEAN Expert ©

Development plan workshop

Page 12: LEAN Product Development (LPD)

12Itzhak 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 (LPD)

13Itzhak Ben-Levy LEAN Expert ©

The process

Time – days / weeks / month

ACTIVITIES

LEGENTFUNCTIONAL

DEPARTMENTS

Main milestones

Page 14: LEAN Product Development (LPD)

14Itzhak 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 activities• Discover Unknown - unknown• Team identity and emotional commitment• Common language among team members• To do list identifying new corrective actions

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

Page 15: LEAN Product Development (LPD)

15Itzhak Ben-Levy LEAN Expert ©

Page 16: LEAN Product Development (LPD)

16Itzhak Ben-Levy LEAN Expert ©16

Value to the customer

• Solving customer Problems

• Exploiting Opportunities

• The product should Look good

• The Customer should Feel good

Page 17: LEAN Product Development (LPD)

17Itzhak Ben-Levy LEAN Expert ©17

QFD shorten cycle time by:1. Understanding value to the customer2. Exploiting customer needs3. Deriving and consolidation of the

requirements from customer needs4. Prioritizing requirements 5. Allocating requirements to the project

team

Page 18: LEAN Product Development (LPD)

18Itzhak Ben-Levy LEAN Expert ©

ONCE

PRICE = PROFIT + COST

What the customer

pays

"by product" of the design

Determined by the

corporate

Page 19: LEAN Product Development (LPD)

19Itzhak Ben-Levy LEAN Expert ©

NOW

COST = PROFIT - PRICE

Determined by the

corporate

Determined by the

competitorsDetermined

to the project manager

DTC - Design To Cost

Page 20: LEAN Product Development (LPD)

20Itzhak Ben-Levy LEAN Expert ©

How the engineer now how to design?

casting welding

machiningforging

Sub contracting riveting

The cost target determined it

Page 21: LEAN Product Development (LPD)

21Itzhak Ben-Levy LEAN Expert ©

Not important

Important

Low High

Requirements(QFD)

Accept all

Consider to delete

delete

challenge

ImplementationCost)DTC(

Reduce requirementsAnd cost

Page 22: LEAN Product Development (LPD)

22Itzhak Ben-Levy LEAN Expert ©

Cost Reduction workshop

Projectmanager

DFMA ToolsFacilitator

Challenge the design

Multidisciplinary Team

• Requirements• Architecture• Technology• Assembly

• Reuse• COTS• Standards• Symmetry

• Tolerances• No. of Parts• Tests• Commonality

Page 23: LEAN Product Development (LPD)

23Itzhak Ben-Levy LEAN Expert ©

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How to integrate the production and procurement into development process

The project manager should requirea real cost status in each gate

Multidisciplinary Team

Page 24: LEAN Product Development (LPD)

24Itzhak Ben-Levy LEAN Expert ©

Engineering

Requirements ReductionCost Reduction

Supplier

Suppliers costs reduction

Costs drivers

Requirements Priorities

Page 25: LEAN Product Development (LPD)

25Itzhak Ben-Levy LEAN Expert ©

"What's it in for me?" Project Manager

• Shorten Time to Market • Reducing manufacturing costs• Reduction of problem solving meetings of the

project. • The project team itself solves the most problems

and takes its responsibilities without management involvement.

• Information provided to management is more reliable and realistic with maximum transparency

• Introduction of a culture that allows to deal with complex issues and find solutions agreed upon in a very short time.