Simple tools how to implement lean product development

1. LEAN Product Development
Implementation
Itzhak Ben-Levy - LEAN Expert
itzhak@benlevy.co.il
www.benlevy.co.il
August 2012
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2. The Traditional way
It is Too many parts
expensive Nobody gave me
The target cost
I cant assemble it
The requirements
were changed
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3. The Development Problems
• Long development cycle times
• Many redevelopment cycles
• High development costs
• Long production cycle times
• High production costs
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4. LEAN
LEAN Manufacturing
LEAN Product Development
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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
communication
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6. LPD workshop
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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 actions
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9. Value to the customer
• Solving customer Problems
• Exploiting Opportunities
• The product should Look good
• The Customer should Feel good
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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
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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 TOOLS
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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 INSPECTION
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13. DTC
PRICE - PROFIT = COST
Determined
by the
competitors
Determined Determined
by the to the project
corporate manager
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14. How the engineer now how
?to design
Sub
contracting riveting
casting welding
forging machining
The cost target determined it
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15. Reduce requirements
And cost
Requirements
(QFD)
challenge
Accept all
Important
Consider to delete
Not delete Implementation
important Cost
High (DTC)
Low
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16. Suppliers
costs reduction
Supplier Engineering
Costs drivers
Requirements
Priorities
Cost Reduction Requirements Reduction
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